546 E-1

Even after reading it, carefully keep it, making clear
to all personnel concerned where its kept so that

the operator, mechanic or supervisor will have an
access to it whenever he wants to read or refer to it.
Be sure to read this Operation Manual for
you to use this product safety and correctly.
Thank you for purchasing
YANMAR product.
I.B.C.No. 09-6N18(A)-V-H-28E
2009.6.18R
6N18(A)L-V
SERIES
CONTENTS
F-1
CONTENTS
Page
PREFACE ................................................................................................................................... 0-1
1. Foreword ................................................................................................................................ 0-1
2. Terms & Symbol Marks ......................................................................................................... 0-3
3. Precautions on Safety ............................................................................................................ 0-4
3-1. Basic Precautions ................................................................................................................0-4
3-2. Precautions on Operation ....................................................................................................0-7
(1) Prior to Staring of the Engine .........................................................................................0-7
(2) During a Run ..................................................................................................................0-7
(3) When Stopping the Engine ............................................................................................0-8
3-3. Precautions on Maintenance ................................................................................................0-9
(1) Precautions Prior to Maintenance Servicing ..................................................................0-8
(2) Precautions During Maintenance Servicing .................................................................0-10
(3) Precautions at Completion of Maintenance Servicing ................................................. 0-11
4. List of Safety Labels ............................................................................................................ 0-12
5. Lifting Procedures for Engine .............................................................................................. 0-13
1. ENGINE DESCRIPTION ....................................................................................................... 1-1
1-1. Engine Specification .............................................................................................................1-1
1-2. Types of Accessories & Attachments ...................................................................................1-3
1-3. Sectional View of the Engine ...............................................................................................1-4
1-4. Engine Outline & Device Arrangement ................................................................................1-5
2. STRUCTURE OF MAJOR PARTS ........................................................................................ 2-1
3. TABLE OF ENGINE STANDARD ADJUSTMENTS .............................................................. 3-1
4. OPERATION .......................................................................................................................... 4-1
4-1. Operational Preparation ..................................................................................................4-1
4-1-1. Lubricating Oil System .........................................................................................4-2
4-1-2. Fuel Oil System ...................................................................................................4-4
4-1-3. Cooling Water System .........................................................................................4-7
4-1-4. Boost Air System .................................................................................................4-7
4-1-5. Starting Air System ..............................................................................................4-8
4-1-6. Control and Protective Devices ............................................................................4-8
4-2. Starting ..........................................................................................................................4-8
1) Starting operation procedures ....................................................................................4-8
2) Corrective actions to be taken in starting failure ..........................................................4-9
3) Checks to be made immediately after starting ...........................................................4-10
4-3. Running .......................................................................................................................4-10
1) Initial Running-in Operation ......................................................................................4-10
2) Steady (Routine) Running ........................................................................................4-10
4-4. Stopping .......................................................................................................................4-13
4-4-1. Stopping in Normal Running ...............................................................................4-13
4-4-2. Emergency Stop ................................................................................................4-14
4-4-3. Disposal After an Emergency Stop .....................................................................4-14
4-5. Changeover to Heavy Fuel Operation and Heavy Fuel Operation (Appendices) ...............4-15
4-5-1. M.D.O. CHANGE OVER..........................................................................................4-15
4-5-2. H.F.O. DIRECT START...........................................................................................4-16
4-6. Cleaning the turbine with water of RH..3 type turbochargers (for auxiliary engine) ...........4-17
2009.6.5R
CONTENTS
F-2
5. FUEL OIL, LUB. OIL & COOLING WATER ........................................................................... 5-1
5-1. Fuel Oil .................................................................................................................................5-1
5-1-1. Quantity Criteria of Fuel Oil ..................................................................................5-1
5-1-2. Quality Criteria of Blended Fuel Oil .......................................................................5-2
5-1-3. Properties of Fuel Oil at the Engine Inlet ..................................................................5-2
5-1-4. Characteristics of Heavy Fuel Oil and Influence on Engines ....................................5-3
5-1-5. How to Find out the Heavy Fuel Oil Heating Temperature .......................................5-5
5-1-6. How to Find out the Viscosity of Blended Oil ............................................................5-6
5-2. Lubricating Oil ................................................................................................................5-7
5-2-1. Choosing the Lub. Oil ..........................................................................................5-7
5-2-2. Control on Lub. Oil ...............................................................................................5-8
1) Control Criteria ..........................................................................................................5-8
2) Oil Change Criteria ....................................................................................................5-8
5-2-3. List of Lub. Oil Brands ..........................................................................................5-9
5-3. Cooling Water (Engine Jacket Water) ............................................................................5-10
5-3-1. Criteria on Cooling Fresh Water .........................................................................5-10
5-3-2. Selection of and Control on Corrosion Inhibitor ...................................................5-10
6. MAINTENANCE CHECKING ................................................................................................. 6-1
6-1. Precautions in Maintenance Checking .............................................................................6-1
6-2. Table of Periodical Checking ...........................................................................................6-2
1) Table of Routine Maintenance Checking .....................................................................6-2
2) Checking Table for Engine Using Marine Diesel Oil .....................................................6-3
3) Checking Table for Engine Using Heavy Fuel Oil (R.W. No.1 at...) ...............................6-6
6-3. Routine Maintenance Checking & Adjusting Procedures ..................................................6-9
6-3-1. Measurement of Running Performance ....................................................................6-9
6-3-2. Measurement of Max. Combustion Pressure (Pmax) .............................................6-10
6-3-3. Regulation of Fuel Injection Volume (Rack Scale) .................................................6-11
6-3-4. Adjustment of Fuel Injection Timing ........................................................................6-12
6-3-5. Checking of Fuel Injection Valve & Adjustment of Injection Pressure ....................6-13
6-3-6. Adjustment of Suc./Exh. Valve Head Clearance ....................................................6-18
6-3-7. Adjustment of Lub. Oil Pressure .............................................................................6-19
6-3-8. Adjustment of Lub. Oil Temperature .......................................................................6-20
6-3-9. Adjustment of Fuel Oil Pressure .............................................................................6-22
6-3-10. Checking of Cyl. Jacket Cooling Water Thermostatic Valves ...............................6-23
6-3-11. Cleaning of Lub. Oil Bypass strainer ....................................................................6-24
6-3-12. Cleaning of Lub. Oil Strainer .................................................................................6-29
6-3-13. Cleaning of Fuel Oil Filter .....................................................................................6-31
6-3-14. Cleaning of Strainer/Filter Element .......................................................................6-33
6-3-15. Washing of Turbocharger Blower...........................................................................6-33
6-3-16. Maintenance of Pressure Gauge ..........................................................................6-37
6-3-17. Measurement of Crankshaft Deflection ................................................................6-39
6-3-18. Adjustment of Fuel Injection Pump Pinion Lubricating Volume
(for Engine Using H.F.O.) .....................................................................................6-42
6-3-19. Maintenance of Fuel Oil Seal Pot (for Engine Using H.F.O.) ................................6-42
6-3-20. Check & Replacement of Anticorrosive Zinc ........................................................6-43
7. MAINTENANCE SERVICING ................................................................................................ 7-1
7-0. Precautions in Maintenance Servicing .............................................................................7-1
1) Precautions on Safety ................................................................................................7-1
2) Precautions in Dismantling, Servicing & Reassembly ..................................................7-3
3) Precautions at Completion of Maintenance Servicing ..................................................7-4
4) Handling Procedures for Turning Gear Device ............................................................7-4
5) Handling Procedures for hydraulic Jack ......................................................................7-5
7-1. Cylinder Head & Its Accessories ...................................................................................7-10
7-1-1. Cylinder Head ....................................................................................................7-10
7-1-2. Suction & Exhaust Valves ..................................................................................7-15
7-1-3. Suc./Exh. Valve Seat .........................................................................................7-16
2009.2.25R
CONTENTS
F-3
7-1-4. Suc./Exh. Valve Guide .......................................................................................7-18
7-1-5. Suc./Exh. Valve Bridge & Its Guide ....................................................................7-19
7-1-6. Valve Rotator .....................................................................................................7-19
7-2. Piston & Connecting Rod ..............................................................................................7-20
7-2-1. Piston & Piston Pin ............................................................................................7-20
7-2-2. Connecting Rod .................................................................................................7-23
7-2-3. Crank Pin Metal .................................................................................................7-24
7-2-4. Connecting Rod Bolt ..........................................................................................7-24
7-3. Cylinder Block & Cylinder Liner .....................................................................................7-26
7-3-1. Cylinder Block ...................................................................................................7-26
7-3-2. Cylinder Liner ....................................................................................................7-26
7-4. Main Bearing & Crankshaft ...........................................................................................7-29
7-4-1. Main Bearing .....................................................................................................7-29
7-4-2. Crankshaft .........................................................................................................7-36
7-5. Timing Gear, Camshaft & Suc./Exh. Swing Arm ............................................................7-37
7-5-1. Timing Gear .......................................................................................................7-37
7-5-2. Camshaft ...........................................................................................................7-39
7-5-3. Suc./Exh. Swing Arm .........................................................................................7-40
7-6. Fuel Injection Pump & Pump Driver ...............................................................................7-41
7-6-1. Fuel Injection Pump ...........................................................................................7-41
7-6-2. Fuel Injection Pump Driver .................................................................................7-44
7-7. Governor & Governor Gear ...........................................................................................7-45
7-7-1. Governor ............................(See the separate-vol. manual on hydraulic governor.)
7-7-2. Governor Gear ...................................................................................................7-45
7-7-3. Coupling Adjustment of Governor Gear ..............................................................7-47
7-8. Lub. Oil Pump, Lub. Oil Pressure Regulating Valve & Lub. Oil Cooler ............................7-48
7-8-1. Lub. Oil Pump ....................................................................................................7-48
7-8-2. Lub. Oil Cooler ...................................................................................................7-50
7-9. Cooling Water Pump .....................................................................................................7-52
7-10. Fuel Oil Feed Pump ....................................................................................................7-53
7-11. Suction/Exhaust System .............................................................................................7-54
7-11-1. Boost Air Cooler ...............................................................................................7-54
7-11-2. Exhaust Manifold .............................................................................................7-56
7-11-3. Turbocharger ............................. (See the separate-vol. manual on turbocharger.)
7-12. Air Motor ....................................................................................................................7-57
7-13. Electromagnetic Pickup ...............................................................................................7-58
7-14. Stopping Air Piston .....................................................................................................7-59
8. PRINCIPAL DIMENSIONS & PART MASS FOR DISASSEMBLY & SERVICING ................ 8-1
9. TABLE OF TIGHTENING TORQUES OF MAJOR BOLTS ................................................... 9-1
10. CLEARANCES & WEAR LIMITS OF MAJOR PARTS ...................................................... 10-1
11. TROUBLESHOOTING & COUNTERMEASURES ............................................................ 11-1
Parts List & Figure ................................................................................................................... Appended
ATTACHED
Service Manual for the Engine Air Starters
Yanmar Service Networks
2009.2.25R
CONTENTS
F-4
MEMO
PREFACE
0-1
PREFACE
Thank you for purchasing a YANMAR Diesel Engine.
1. Foreword
This Operation Manual has been prepared for your safe and effective use of the engine. Read through this
Operation Manual and fully understand the safety precautions and precautions regarding the operation,
checking and servicing before using this engine.
(1) Keep this Operation Manual at a clearly identified place accessible for the operator to refer to it at
any time.
(2) The text and illustrations of this Operation Manual may partly disagree with engines of some speci-
fications.
For such engines, refer to the Engine Specification and Final Document we have submitted you
separately.
Also note that used parts and the content of this Operation Manual description of this engine are
changed without notifying the user beforehand for improving the quality and performances of
engine or for safety.
(3) For the following devices, refer to the corresponding operation manuals separately attached.
Turbocharger
Hydraulic governor
Other attachments of special specifications
(4) In this manual, the numerical values are based on the SI system (International System of Units).
However, the numerical values based on the conventional unit system are also given in brackets.
(5) Replacement parts should be our genuine parts or specified parts. Order a part to your nearest
sales or service agent of Yanmars parts. When ordering a part, clearly specify the Part Name (part
description) and Part No., and the Model and manufactures Serial No. of the engine.
(6) If you should have lost or damaged this Operation Manual, or if you have any questions and advice,
please contact us or your nearest sales or service agent (shown in the service network list "YAN-
MAR Worldwide Service" appended to this manual).
(7) If you transfer this engine, also transfer this Operation Manual, Final Document and Records of
Shop Trial with the engine to the next owner.
(8) If you use this engine for an application or under service condition other than those specified, or if
you handle it not in accordance with this Operation Manual, an accident or a failure may be caused.
Please contact us or your nearest sales or service agent before changing any technical data of the
engine or modifying the engine after it has been delivered. Never modify the engine without consult-
ing us.
(Foreword)
(Volume:14pages) 2006.6.23R
PREFACE
0-2
For safe use of your engine.
Be sure to abide by -marked DANGERs, WARNINGs and CAUTIONs described in this Manual.
As far as safety is concerned, they are particularly important parts of instructions.
The following shows the safety marks used for caution indications in this Operation Manual and
safety labels attached to this product and explains their meaning.
It indicates that a danger of possible death or serious injury is very great
when the proper precautions is not followed.
It indicates that there is a danger of resulting in death or serious injury when
the proper precautions is not followed.
It indicates that there is the possibility of resulting in injury or serious
damage to the engine when an advice on safety handling or the
proper precautions is not followed.
Where the safety labels are posted is shown in page 0 -12.
The cautions prefixed with the mark in this Operation Manual are especially important for safe
handing of this product. A failure to observe this caution may incur a deterioration of performances or
trouble/accident of this product. Therefore, be sure to observe the items.
(For safe use of your engine)
PREFACE
0-3
2. Term & Symbol Marks
1) The major terms used in this Operation Manual are defined as follows:
2) The following symbol marks are used in the safety labels shown in this Operation Manual and
posted on the engine.
(1) Caution marks and signal words
It indicates that a danger of possible death or serious injury is very great
when the proper precautions is not followed.
It indicates that there is a danger of resulting in death or serious
injury when the proper precautions is not followed.
It indicates that there is the possibility of resulting in injury or serious
damage to the engine when an advice on safety handling or the
proper precautions is not followed.
It indicates a handing caution which, if not observed, may incur a deteriora-
tion of performance or a trouble/accident of this product.
(2) Symbol marks
(a)Caution marks (b)Others
Front part of engine: Part opposite to the flywheel end
Rear part of engine: Part on the flywheel end
Operating side: Left side as viewed form the flywheel end (fuel injection pump side)
Non-operating side: On the right as viewed from the flywheel end (exhaust pipe side)
CW rotation: Clockwise rotation as viewed from the flywheel end
CCW rotation: Counterclockwise rotation as viewed from the flywheel end
Cylinder No: Assigned in the ascending order from the cylinder nearest to the flywheel end
6 5 4 3 2 1
Non-operating Side
Flywheel
Generator
Fuel Injection Pump
Operating Side
Caution
on explosion
Caution on fire
Caution on
hazardous noise
Caution on
rotating part
Caution on
high temperature
Refer to another page,
section or chapter of this
Operation Manual or other
document.
High pressure
air inside
(Terms & Symbol Marks)
2004.11.25R
PREFACE
0-4
An accident may occur if the safety rules are not followed.
3. Precautions on Safety
3-1. Basic Precautions
Strict Observance of the Safety Rules
When running the engine or servicing it for its maintenance, observe the safety rules, precautions on
safety and work procedures.
When carrying out a joint work, work according to the predeter-
mined signs.
Way of pre-work arrangement
(1) According to kind of work required
(2) Everyone to contemplate and consider
(3) Everyone to understand well
(4) Fix the most suitable way to work
Wear the proper protective garment. Don't wear oil
smudged work clothes because they are prone to catch
fire.
Wear protectors such as helmet, safety goggles, safety
shoes, protective mask, protective glove, life-line, etc.,
depending on the nature of work required.
When working on the engine, use the specified engine
tools. Use jigs or tools suitable for particular work because
use of a wrong tool causes an injury.
While at work, do not jump on and off the engine.
For working, install a work bench fitted to the size of your engine to secure a good footing. Don't work
in a dangerous position.
W
O
R
K
Before starting
a work
(1) Safety has priority over
all the works.
(2) Safety is more impor-
tant than any other
duties.
(3) It is needless to say
that "Safety First"
means that safety has
priority over working
efficiency.
(4) Safety is the foundation
for working efficiency.
Safety is never contra-
dictory to working effi-
ciency.
Safety helmet
Safety shoes
Be properly clothed
Life-line
Protective glove
(Safety Precautions / Basic Precautions)
PREFACE
0-5
No Modification, Please.
When you want to modify your engine, consult us or your nearest sales
or service agent in advance. Yanmar can not be responsible for an acci-
dent resulting in injury or death or an engine trouble resulted from unau-
thorized modification.
Your engine and its safety devices have been sealed for the sake of
safety. Don't break or tamper with a seal indiscreetly.
If a sealing is missing, take a proper step of promptly contacting us or
your nearest sales or service agent for ensuring the proper initial set-
ting.
Observe the precautions for ensuring safety.
Check of Safety Devices
Check the all the safety devices of your engine have been set normally.
If a safety device is wrongly used, it leads to a serious accident resulting in injury or death.
Promptly repair a cover a rotating part, a heat shielding cover for exhaust pipe, a protective cover of
the heating region or the like, if found damaged.
Never run the engine while the cover of a rotating part is removed. Otherwise dur-
ing operation, your hand, body or clothing may be caught in the rotating part, result-
ing in your injury.
Be Cautious of Handling of a High-temperature or High-pressure Spot.
Take care not to get burnt.
During running and immediately after the engine has stopped, the whole engine is heated. Take care
not to get burnt.
When changing cooling water, lubricating oil or filter immediately after the engine has
stopped, proceed to work only after the temperature has lowered.
Do not touch a high-temperature region such as the exhaust pipe or pressure indicator
cock of engine with bare hands.
Do not touch the heater and heated sections of fuel oil system with bare hands.
Since the pressure indicator becomes hot, be sure to wear gloves when taking read-
ing.
If you uncap the radiator or fresh water tank, vapor or hot water may blow up, causing
you to get burnt.
Stop the engine and wait until the temperature has dropped. Then, wrap the cap with
cloth and slowly loosen it to release the internal pressure. After that, remove the cap.
S
ealed ?
PREFACE
0-6
Be Cautious of Handling of Fuel & Lubricating Oil.
If fire is brought close to fuel and/or lubricating oil, there is the possibility of catching
fire.
(Particularly the fuel is highly flammable and dangerous.)
Fire should be strictly prohibited in the engine installed place (engine room).
Check for leak of fuel oil and lubricating oil. If you find a defective point, repair it and
wipe out leaked fuel or lubricating oil.
Store the fuel oil and lubricating oil at the specified place and do not allow persons
other than those concerned to handle them.
Unnecessary flammables in the engine installed place (engine room) may cause fire.
Therefore, store these flammables in another specified place.
Ventilate Well.
Exhaust gas emitted from an engine is dangerous.
If Exhaust gas is leading, promptly repair such a leaking
point at the exhaust pipe.
Ventilate well the indoor engine installed place (and/or the
engine room.)
Take care that the room does not fall short of the air (oxy-
gen) because the turbocharger takes in a great volume of
air.
While charging the battery, there is danger of
catching fire because hydrogen gas is gen-
erated.
Installing of a Fire Extinguisher and First-aid Kit
Install a fire extinguisher against a possible fire, and check how to use
it.
Fix a safekeeping place for a first-aid kit, and install it there.
Fix the actions to be taken when fire or an accident has occurred.
Establish a means of reporting to emergency medical institution such
as an emergency hospital, and have its telephone number written
down.
CAUTION:
FLAMMABLES
NO SMOKING
Ventilate well to prevent gas intoxication.
Inhaling exhaust gas is very dangerous.
When working indoors, sufficiently
ventilate the room.
FIRE
EXTINGUISHER
PREFACE
0-7
3-2. Precautions on Operation
(1) Prior to Starting of the Engine
Start the Engine after Signaling
Check if no one is around the engine.
If someone is found near the engine, give him a sign that the engine will be
started. Only then start it.
Check the holding capacities of fuel, oil, air, etc.
Be sure to detach the turning device once the engine is started, and keep
it at it's fixed housing spot.
Turn on the power supply of the engine protection device before starting up the engine.
After the engine has been stopped for a long time or after the engine has been serviced, be sure to
start up the engine at the engine side.
If the rotational speed rises extremely rapidly or if you find an usual sound or fume, immediately set
the start/stop lever in the STOP position to stop the engine.
Check After the Engine Is Started
Check if pressure values of each instrument/gauge board are normal.
Check if there are no unusual sound and abnormal heat buildup.
Check for any leakages of fuel, oil, air, etc., and if a leakage is found, promptly repair.
Except in case of emergency, apply the load after a warming-up.
(2) During a Run
Keep watching the pressure and temperature or check for unusual sound and abnormal heat buildup.
Check whether the engine fully shows its proper performances and record the check results. (Refer to
the Records of Shop Trial, then record the check results on the Engine Log.)
Take care not to be caught in a rotating part.
Never allow your hands, body and clothing to make contact or bring close to any rotat-
ing part.
During running and immediately after the engine has stopped, the whole engine is
heated. Therefore, take care not to get burnt.
Take care not to allow your hands, body and clothing to make contact with the turbo-
charger, exhaust manifold, exhaust pipe and/or engine as whole.
If any abnormality is detected, immediately stop the engine and repair it.
Take care not to get hearing loss.
Put an ear protection in engine-room during running, because can cause hearing loss.
(Safety Precautions / Precautions on Operation)
2003.10.20R
PREFACE
0-8
(3) When Stopping the Engine
Do not stop the engine simultaneously with load shutoff.
Except in case of emergency, keep running the engine without load after load shutoff.
Keep the engine ready for being started up.
Promptly repair the points that have been troubling during a run.
Do not open the side cover of crankcase for at least 10 minutes after having stopped
the engine. Otherwise, the entry of external air may result in explosion.
Immediately after the engine has stopped, the whole engine is heated. Therefore, take
care not to get burnt.
charger, exhaust manifold, exhaust pipe and engine as a whole.
If you attempt to drain oil while the engine is still hot, take care not to get burnt with
splash of oil.
If you disassemble the cooling water system while the engine is still hot, vapor or hot
water may blow out, causing you to get burnt.
Wait until the engine becomes cool, then wrap the disassembling part with cloth or the
like and slowly loosen it.
(Safety Precautions / Precautions on Operation)
PREFACE
0-9
3-3. Precautions on Maintenance
(1) Precautions Prior to Maintenance Servicing
Indication of Warnings in Checking and Servicing
While checking and/or maintenance servicing the engine, post a notice
on a warning indicating board for danger prevention.
Strive for safety, maintaining a close contact with the respective parties
concerned.
Strive to prevent a danger from emerging, forbidding other than the par-
ties concerned to enter the engine installed place (and/or the engine
room), for instance.
Immediately After an Engine Stop
Do not open the side cover of crankcase for at least 10 minutes after having stopped
the engine. Otherwise, entry of external air may result in explosion.
Immediately after the engine has stopped, the whole engine is heated. Therefore, take
care not to get burnt.
charger, exhaust manifold, exhaust pipe and engine as a whole.
If you attempt to drain oil while the engine is still hot, take care not to get burnt with
splash of oil.
If you disassemble the cooling water system while the engine is still hot, vapor or hot
water may blow out, causing you to get burnt.
Wait until the engine becomes cool, then wrap the disassembling part with cloth or the
like and slowly loosen it.
Preparation Prior to Working
Since a working area will be stained/smudged, put it in good order.
Prepare engine jigs and tools ready to use.
Prepare oil, genuine parts, waste cloth, wire, etc. according to the nature of work to be done.
Secure a work bench fitted to the height of the engine.
(Safety Precautions / Precautions on Maintenance)
PREFACE
0-10
(2) Precautions During Maintenance Servicing
Check in Course of Work
For a joint work strive for elimination of a possible danger by keeping
alert to the surroundings.
Tie such an accessory detached in work to a stable post or spot so that
it will not fall down.
For a work at a height, put on the safety belt or life-line.
According to the condition of working, wear protectors.
Be careful of oil stained or smudged protective glove because working
with such a glove might lead to a damage of parts or a personal injury
as your hands are apt to slip.
Wipe off or mop up spilled fuel or oil at once because, if left alone, it is
dangerous as it causes a slip.
Prepare a box to accommodate removed parts in advance so that they will not be lost nor damaged.
If necessary, provide setting marks before disassembling the engine so that you can reassemble it in
the proper reassembling sequence.
Reassemble the setting marked portions with reference to the setting marks.
Tighten the bolts and nuts to the specified torque or hydraulic pressure.
Use of the Proper Tools
Use the specified engine tools to prevent the damage of the respective bolts and nuts of the engine.
When handling a heavy thing, follow the slinger's instructions.
In advance of using exclusive tools, check the function of these tools.
Carefully check for any damages to rubber hose and joints of hydraulic jacks.
Use the specified lifting gear, hook, rope, etc.; and pay attention to safety when handling a heavy
thing particularly.
Precautions in Use of Fire
In such works with welder, electrical tools
and grinder, be careful of sparking.
Since there is the possibility of catching
fire, try not to leave combustibles such as
fuel, lubricating oil and used waste cloth in
a working area.
OPERATION
MANUAL
C
o
u
t
i
o
n
:
F
ire
and Flam
m
a
b
le
s
PREFACE
0-11
Precautions in Checking the Electrical System
Shut off the power supply before starting the work. Otherwise, a fire may occur or you
may receive electric shock.
When checking the battery system, be sure to disconnect the earth cable
() terminal. Otherwise, the negative terminal may be short-circuited by mistake,
resulting in fire.
The strong acid battery electrolyte put on your skin or eyes will cause inflammation. If
the battery electrolyte should be put on your skin or eyes, immediately flush it with
fresh water, then consult a physician.
Precautions for Using Organic Solvent
Since an organic solvent is highly volatile, liable to be gasified and absorbed by worker through his
breathing as it vaporized, pay close attention to ventilation when handling it.
Since a highly concentrated organic solvent has the property of dissolving fats and oils and is
absorbed by worker through his skins, be careful of handling it.
When working with such a solvent, be sure to wear rubber gloves.
(3) Precautions at Completion of Maintenance Servicing
Check of Work Finish
Check if detached parts have been refitted at the specified spots in the total
number.
Check if the damaged parts have been replaced with the good ones.
Return tools, lifting gear, hook, rope, etc. used to the former safekeeping place.
Remove fuel and oil from the engine installed place (and/or the engine room).
Keep the engine installed place (and/or the engine room) in order and tidy so
that it will not interfere with daily operation.
Before starting the engine, check various parts to see if there is no abnormality.
Refer back to 3-2. Precautions on Operation, (1) Prior to Starting of the
Engine.
Proceed t a load run, and check that the performance does not differ from that
existed prior to the maintenance servicing.
Refer back to 3-2. Precautions on Operation, (2) During a Run.
As soon as a load run is completed, enter records of performance as well as
the nature of maintenance servicing in your Engine Log. (Keeping of records
and then reporting of work completion)
Remove such as a standing signboard, and contact the respective parties con-
cerned for reporting the completion of work.
E
N
G
IN
E L
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KEEP TIDY
PREFACE
0-12
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(Safety Precautions / List of Safety Labels)
2002.8.30R
4. List of Safety Labels
PREFACE
0-13
5. Lifting Procedures for Engine
Falling of the engine or generating set during its lifting or carriage is very dangerous if so happened.
In time of a load lifting work, observe the following items in order to prevent an accident:
Use the lifting wire rope, shackle, etc. that are suitable for lifting weight.
Choose the wire rope length so that the engine or common bed does not lean to one side during lift-
ing.
Put a cushioning material such as padding between the wire rope and the engine or driven machine
(generator, for instance) which the wire rope comes into contact with otherwise.
Choose such a cushioning material as will not be damaged not removed during lifting, then attach it
not to allow its contacts with the engine or driven machine to be damaged.
Do not enter an area below the lifting load.
Lifting sling attaching points
1) Common bed set
The "Hang up This Point" labels have been
stuck on the common bed.
2) Engine singly
Fit the (optionally available) exclusive lifting
slings to cylinder head clamping bolts of the
No. 2 and No. 5 cylinders close to the center of
the engine.
Haul up the cylinder heads under the specified
hydraulic pressure tightened state.
Keep the lifting angle of the wire rope within 60
degrees.
3) Driven machines (generator, pump, etc.)
For the wire rope attaching points, refer to the
respective Operation Manuals.
Hang up This Point
No.6 No.1
60
HOOK
HOOK
No.1 No.6
60
(Safety Precautions / Lifting Procedures Engine)
PREFACE
0-14
MEMO
1.ENGINE DESCRIPTION
1-1
1. ENGINE DESCRIPTION
1-1. Engine Specification (1/2)
Model Unit 6N18L-DV 6N18L-UV 6N18L-SV 6N18L-EV
Type --- Vertical, water-cooled, 4-cycle diesel engine
Combustion chamber --- Direct injection type
No. of cylinders --- 6
Cylinder bore mm 180
Stroke mm 280
Total cylinder displacement --- 42.75
Compression ratio --- 16.5
Rated speed of revolution min
-1
(rpm) 720 or 750
Direction of rotation of
crankshaft
--- Counterclockwise as viewed from the flywheel end (XL)
Operating side --- On the left as viewed from the flywheel end
Order of firing --- 1-4-2-6-3-5-1
Supercharging system --- Exhaust gas turbine supercharger (turbocharger) with air cooler
Cooling system --- Dual fresh water line cooling.
Lubricating system ---
Forced lubrication
(system oil also used as turbocharger lub.oil)
(system oil also used as rocker arm lub.oil)
Lubricating oil sump sys-
tem
--- Sump incorporated in common bed
Starting system --- Air motor starting
Dimen-
sions
Overall length mm 2,696
Overall width mm 1,315
Overall height mm 1,935
Mass (of engine singly) kg
6,500
(may vary as depending on specification)
No. of cylinders
Engine series
Cyl. bore (in cm)
W/O"A": 720 or 750min
-1
W/"A": 900 or 1000min
-1
Marine auxiliary/Land use
Degree of supercharging
6 N 18 A L EV
Constitution of Model Designation
1 2 3 4 5 6
Flywheel
Configuration of Cylinders
(Engine Specification)
1-2
1-1. Engine Specification (2/2)
Model Unit
6N18AL-
HV
6N18AL-
DV
6N18AL-
UV
6N18AL-
SV
6N18AL-
EV
Type --- Vertical, water-cooled, 4-cycle diesel engine
Combustion chamber --- Direct injection type
No. of cylinders --- 6
Cylinder bore mm 180
Stroke mm 280
Total cylinder displacement l 42.75
Compression ratio --- 16.5
Rated speed of revolution min
-1
(rpm) 900 or 1,000
Direction of rotation of
crankshaft
--- Counterclockwise as viewed from the flywheel end (XL)
Operating side --- On the left as viewed from the flywheel end
Order of firing --- 1-4-2-6-3-5-1
Supercharging system ---
Exhaust gas turbine supercharger (turbocharger) with
air cooler
Cooling system --- Dual fresh water line cooling.
Lubricating system ---
Forced lubrication
(system oil also used as turbocharger lub.oil)
(system oil also used as rocker arm lub.oil)
Lubricating oil sump system --- Sump incorporated in common bed
Starting system --- Air motor starting
Dimen-
sions
Overall length mm 2,696
Overall width mm 1,315
Overall height mm 1,935
Mass (of engine singly) kg
6,500
(may vary as depending on specification)
No. of cylinders
Engine series
Cyl. bore (in cm)
W/O"A": 720 or 750min
-1
W/"A": 900 or 1000min
-1
Marine auxiliary/Land use
Degree of supercharging
6 N 18 A L EV
Constitution of Model Designation
1 2 3 4 5 6
Flywheel
Configuration of Cylinders
(Engine Specification)
2003.4.17R
1-3
1-2. Types of Accessories & Attachments
Accessory/Attachment Type Remarks
Supercharger Air-cooled exhaust gas turbine
Boost air cooler Plate finned multitubular
Governor Hydraulic
Fuel injection pump Bosch
Fuel valve Non-cooled perforated
M.D.O.feed pump Gear For marine diesel oil
Fuel oil filter
Heat-insulating, manual back-washing,
duplex, changeover notch wire
For engine inlet
Lub.oil pump Gear Pressure regulating valve integrated
Lub.oil cooler Low finned tube multitubular w/automatic temperature control valve
Lub.oil strainer Duplex, changeover notch wire Manual back-washing
Lub.oil by-pass strainer Centrifugal
Lub.oil tank Tank incorporated in common bed
Cooling water pump Centrifugal Cylinder jacket side, cooler side
Lub.oil priming pump Screw
Air motor Turbine
(Types of Accesories & Attachments)
1-4
1-3. Sectional View of the Engine
Exh. Manifold
Piston
Boost Air Boost Chamber
Cyl. Liner
Lub. Oil Cooler
Lub. Oil Strainer
Cyl. Block
Main Brg. Bolt
Oil Pan
Mounting Foot
Side Bolt
Crankshaft
Connecting Rod
Camshaft
Pump Housing Cover
Fuel Injection Pump
Protection Ring
Injection Pipe Joint
Cyl. Head
Valve Push Rod Rocker Arm Suc./Exh.Valve
Swing Arm
NON OPERATING SIDE OPERATING SIDE
(Sectional View of the Engine)
1-5
1-4. (1/2) Engine Outline & Device Arrangement
1-4. (2/2)Engine Outline & Device Arrangement
Turbocharger Injection Pump Housing Cover
Fuel Injection Pump
Gauge Panel
Starting Switch
Start/Stop Lever
Governor
Control Position
Selector Switch
Air Motor
Turning Device
Cam Case Cover
Flywheel
Operating Side Engine Rear End
Exh. Manifold Cover
Lub. Oil Thermostatic
Valve
Boost Air Cooler
Cold Water Pump
(on Cooler Side)
Hot Water Pump
(on Cly. Jacket Side)
Hot Water
Thermostatic Valve
Crankcase Safety Valve
Lub. Oil Bypass Strainer
Lub. Oil Priming Pump
Lub. Oil Strainer
Lub. Oil Pressure
Regulating Valve
Lub. Oil Cooler
Lub. Oil Pump
Fuel Filter
Fuel Oil Pressure
Regulating Valve
M.D.O.Feed Pump
Non-operating Side Engine Front End
(Engine Outline & Device Arrangement)
1998.10.20R
1-6
MEMO
2.STRUCTURE OF MAJOR PARTS
2-1
2. STRUCTURE OF MAJOR PARTS
2-1. Outline of Structure
This engine is designed to be a crankcase integrated, suspension metal structure as shown in the below
sectional view.
For its installation, there are the fixed supporting to fix it directly on the common bed and the antivibration
supporting to fix the mounting foot and generator on the common bed via rubber vibration insulators.
Drawing 2-1.
Exh. Manifold
Piston
Boost Air Boost Chamber
Cyl. Liner
Lub. Oil Cooler
Lub. Oil Strainer
Cyl. Block
Main Brg. Bolt
Oil Pan
Mounting Foot
Side Bolt
Crankshaft
Connecting Rod
Camshaft
Pump Housing Cover
Fuel Injection Pump
Protection Ring
Cyl. Head
Valve Push Rod Rocker Arm Suc./Exh.Valve
Swing Arm
NON OPERATING SIDE OPERATING SIDE
(Outline of Structure)
(Volume:6pages)
2-2
2-2. Structure of Major Parts
1) Cylinder block
Provided with side covers on both the operating side and the non-operating side, the cylinder block is a
duplex wall structure made of casting integrating the boost air manifold (boost air chamber), main lubricat-
ing oil pipe and main cooling water pipe.
2) Cylinder liner
Made of a special cast iron, the cylinder liner has the special thermal treated surface. The inner face is
finished with precision honing. On the upper part of inner diameter of the liner, an anti-polish ring is
mounted.
3) Cylinder head
The cylinder head is of the 4-valve type equipped with two suction valves and two exhaust valves and
arranged with a fuel injection valve at the center. The cylinder head is clamped by tightening four bolts
under the hydraulic pressure.
The exhaust valve seat is water cooled, and the fuel injection valve is mounted with a sleeve.
4) Piston and piston rings
The piston is special cast iron. Its upper parts is cooled by the cocktail shaker method using lubricating oil
that passes through the connecting rod and piston pin. The skirt is provided with special coating.
The piston rings are two compression rings, and their sliding surface is chrome-plated. Besides, there is
one oil ring combined with a coil expander whose sliding surface is also chrome-plated.
5) Connecting rod
The big end of a connecting rod is an obliquely split structure, and its mating surfaces are serrated. The
connecting rod bolts are two tap bolts tightened to the specified angle.
6) Crankshaft and main bearings
A balance weight is attached to each arm of the crankshaft by tightening the balance weight clamping bolts
to the specified angle.
The main bearing is of the suspension metal type. At the flywheel-side timing gear case of the No.1 main
bearing, the No.0 main bearing is provided, and it is attached with thrust metal and journal metal.
Each bearing cap is fixed with two mounting bolts and two side bolts on both the operating side and non-
operating side. The mounting bolts are tightened to the specified hydraulic pressure.(The side bolt of the
No.0 main bearing cap is equipped only on the non-operating side.)
7) Camshaft
The suction/exhaust cam and fuel cam form a monoblock structure with the camshaft. It is split in two at
the bearing part between the No.3 & No.4 cylinders.
8) Fuel injection pump
The fuel injection pump is of the Bosch type. The delivery valve is a pressure equalizing valve, and the
plunger barrel is of the top closed type.
The fuel injection timing is adjusted by means of the adjusting bolt of tappet of pump driving gear.
9) Fuel injection valve
The type using the high viscosity fuel oil is cooled with the cooling water running through the fuel injection
sleeve mounted on the cylinder head. A heat transfer bush (copper) is installed between the fuel injection
nozzle and the injection valve sleeve, thus indirectly cooling the injection nozzle. The engine using the MD
oil does not use the indirect cooling system nor a heat transfer bush. The injection pressure is adjusted
with the spring shoe fastened with the adjusting nut.
10) Starting and stopping devices
The engine is started by an air motor using the compressed air.
To stop the engine, the start/stop lever is set in the STOP position. To stop the engine by the remote oper-
ation, the air piston is actuated to set the rack of fuel injection pump at the non-injection position.
The start/stop lever and turning device are interlocked with the respective switches to prevent starting by
erroneous operation.
(Structure of Major Parts)
2002.8.8R
2-3
2-3. Lubricating Oil System
The lubricating oil pump is a gear pump integrating the pressure regulating valve and safety, valve.
The lubricating oil strainers are a notch-wire type strainer and a centrifugal bypass strainer.
The lubricating oil cooler is a unit structure of the multi-tubular type fitted with an automatic thermo-
static valve and a notch-wire type strainer.
The priming pump is a motored screw pump and is mounted on the common bed. The delivery pipe
is connected with the inlet side of the notch-wire type strainer.
The lubricating oil discharged from the pump is regulated of its pressure to the specified value by the pres-
sure regulating valve. Then, the lub. oil passes through the cooler and strainer and then enters the main
gallery of the cylinder block. The lubricating oil line is branched at the main gallery. The oil passes through
each part and returns to the oil pan and then the common bed.
Each lub. oil passage franched off from the main gallery is a drilled hole structure, excluding lines leading
to the pressure regulating valve and governor driving gear.
The oil suction part of the pump varies according to the engine installation types. In the case an engine
installed by the fixed supporting, the fixed suction part is the command bed; in the case of antivibration
supporting, it is oil pan.
Drawing 2-2
(Heavy Fuel Oil Spec.)
(Connecting Rod)
Auto. Thermostatic Valve
Main Gallery
Lub. Oil Cooler
Pressure Regulating
Valve
Pump
Oil Pan
Command Bed
Bypass Strainer,
Centrifugal
Engine Main
Lub. Oil Strainer
Notch-wire Type
Turbocharger
Lub. Oil Strainer
Paper Element Type
Priming Pump
Swing Arm Brg.
Fuel Injection Pump Pinion
Suc./Exh. Valve Rocker Arm
Fuel Injection Pump Tappet Roller
Camshaft Intermed. Gear
Lub. Oil Pump Intermed. Gear
Governor Driving Gear
Cam Bearing
M. Brg. Crank-pin Brg. Piston-pin Brg.
Turbocharger
Piston
Swing Arm Roller Pin
Cooling Water Pump Intermed. Gear
(Lubricating Oil System)
1999.7.2R
2-4
2-4. Cooling Water Pipe System
2-4-1. Cooling Water Pipe System (both fresh water line of the mixing type)
The cooling system of this engine is to cool the engine (cylinder liner and cylinder head) with hot fresh
water and the lubricating oil cooler and boost air cooler with cold fresh water. This cooling system is called
the dual fresh water line cooling system of the mixing type.
Both the cold water pump and the hot water pump are centrifugal pumps equipped to the frontal
part of the engine. The hot water pump is such a structure to incorporate the check valve directly
to the frontal side gear case through the check valve on the delivery side. (The suction parts of
both pumps are caupled in the gear case.)
The temperature of hot water is controlled by the pellet type automatic thermostatic valve.
The temperature of cold water is controlled by a thermostatic valve equipped on the fresh water
cooler side.
The cooling water discharged from the cold water pump passes through the boost air cooler and lubricat-
ing oil cooler, and then returns to the fresh water cooler side. However, a part of the cooling water passes
through the cooling water passage in the cylinder block and flows into the cold water suction side through
the automatic thermostatic valve.
The cooling water discharged from the hot water pump returns to the cylinder jacket, cylinder head and
cooling water collecting pipe and then to the automatic thermostatic valve which controls the temperature
of thus returned cooling water.
The cooling water flown into the cylinder head cools the combustion surface and periphery of fuel injection
valve sleeve and then cools the exhaust valve seat. After that, the cooling water flows into the cooling pipe.
Expansion Tank
Hot Water Pump
Automatic Thermostatic Valve
Cold Water Pump
Cold Water Thermostatic Valve
Boost Air
Cooler
Lub. Oil Cooler
Fresh Water
Cooler
(Sea Water)
Check Valve
Drawing 2-3
(Cooling Water System)
2-5
2-4-2. Cooling Water Pipe System (cold water line sea water spec.)
1) The cooling system of this engine is to cool the engine (cylinder liner and cylinder head) with hot fresh
water and the lubricating oil cooler and boost air cooler with cold sea water.
The cooling system is a dual-line system consisting of the cylinder jacket line and cooler line.
Sea water lines are equipped with a motor-driven centrifugal pump mounted in the marine as the
standard provision.
The cooling fresh water pump in the cylinder jacket line, the centrifugal pump is driven via an idle
gear.
2) The cooling sea water discharged from the cold water pump passes through the boost air cooler and
lubricating oil cooler.
3) A bypass valve is provided at the cooling water outlet side of boost air cooler.
Opening the bypass valve decreases the amount of cooling water flowing through the boost air cooler
and raised the boost air temperature.
4) The cooling water discharged from the hot water pump returns to the cylinder jacket, cylinder head and
cooling water collecting pipe and then to the cooling water expansion tank tank.
5) The cooling water flown into the cylinder head cools the combustion surface and periphery of fuel
injection valve sleeve and then cools the exhaust valve seat. After that, the cooling water flows into the
cooling water cooling pipe.
Fresh (Hot) Water Pump
Fresh (Hot) Water Outlet
(To expansion tank)
Automatic Sea Water Valve
(mount in marine)
Sea Water Inlet
Fresh Water Inlet
Sea Water Outlet
By-pass Valve
Sea Water Pump
(mount in marine)
Boost Air
Cooler
Lub. Oil Cooler
Drawing 2- 4
(Cooling Water System)
2000.10.6R
2-6
2-5. Air & Engine Control System
2-5-1 Engine Start
The starting air circuit is diagramed by continuous in Drawing 2-5.
The starting air supplied from air tank is sent to air filter, reducing valve and safety valve, and consequently
reaches the main circuit valve, which drives air motor.
The control air supplied from control air source is sent to the Shut-off valve V
1.
for interlocking turning gear,
Starting magnetic valve V
2
and reaches the main circuit valve after passing through air filter and check
valve. Besides, the piping layout is so constituted that the control air branched from Starting magnetic
valve V
2
is sent to Speed control valve V
3
and reaches the air piston for F.O. limitation.
The air motor to drive the ring gear is of the turbine type; the starting valve V
2
integrated with the motor, a
solenoid valve equipped with a manual operating; the shut-off valve V
1.
of the turning device section,
mechanical; the stopping valve V
4
for engine stopping, a solenoid valve. For air piston, the double piston
type equipped with one piston each for limiting and stopping injection fuel is adopted.
Drawing 2- 5 Starting Air Circuit & Engine Control Device Layout
2-5-2 Engine Stop
The stopping air circuit is diagramed by broken line in Drawing 2-5. The circuit is a pipeline provided with a
globe valve and the stopping valve V
4
of the solenoid valve type on the way to the air cylinder.
2-5-3 Engine Start (in case of Dead Ship)
When the ship's control air is missing in case of Dead Ship, open the Bypass valve V
5
(normal close),
which is branch off Safety valves, the air is sent to the Shut-off valve V
1
for interlocking the turning gear,
Starting magnetic valve V
2
and reaches the main circuit valve, and consequently has the engine started.
On the other hand, when the ship's electric control power is missing, push the button, which is equipped
with Starting Magnetic valve V
2
, and consequently has the engine started.
2-5-4 Engine Rotational Controls
Constitution of control devices is shown in Drawing 2-5. The control is accomplished by use of the gover-
nor, start/stop lever, fuel injection pumps, air piston and link mechanism of such as levers and shafts to
interlock the control devices.
In starting, the air piston acts on the shaft of a lever interlocking fuel injection pumps to limit the fuel injec-
tion volume, actuates the control valve to gradually releases limiting and works to stop the injection in stop-
ping.
Incidentally, an engine side stopping is done by operating the start/stop lever. The governor equipped on
the operating side of the engine rear part adopts the hydraulic type; the fuel injection pump, the Bosch
type.
No.6
Cylinder
No.1
Cylinder
Control Air Inlet
(0.70~0.98MPa)
Starting Air Inlet
(3.0 or 2.5MPa)
Safety
Valve
Air motor
Air Chamber
Air Piston for Engine Stop &
F.O. Limitation
V3
V4
V5
V1
V2
Turning
Gear
V1: Shut-off valve for start interlock
V2: Starting magnetic valve
V3: Speed control valve
V4: Stopping magnetic valve
V5: Bypass valve
..
029440-00E
2009.3.31R
3.TABLE OF ENGINE STANDARD ADJUSTMENTS
3-1
3. TABLE OF ENGINE STANDARD ADJUSTMENTS
3-1. Assembly Adjustment Values
3-2. Pressure & Temperature Setting Values
Note: For a star( ) given above, refer to the Records of Shop Trial and enter the obtained value here
because it varies according to the engine specification and output.
Item Adjustment Value Remarks
Piston top clearance(A) mm 2.0 0.2
Begins to open(before T.D.C.)
deg.
68
Ends closing(after B.D.C) 50
Valve head clearance(B) mm 0.3 In the cold state
Begins to open(before B.D.C)
deg.
68
Ends closing(after T.D.C) 58
Valve head clearance(B) mm 0.4 In the cold state
Fuel injection pump begins to
deliver(before T.D.C)
deg.

Refer to Records of Shop
Traial.
Injection pressure, fuel injection valve
MPa(kgf/cm
2
) 34.0 0.5(347 5)
Item Setting Value Remarks
Fuel feed pressure
MPa(kgf/cm
2
)
0.49 0.54(5.0 5.5) Marine disel oil(M.D.O)
Refer to Chapter 5,5-1-3 Heavy fuel oil(H.F.O.)
Maximum combustion pressure(Pmax)

Trial.
Lub. oil pressure
0.39 0.44(4.0 4.5) Engine inlet(cooler outlet)
0.1 0.2(1.0 2.0) Turbocharger inlet
Cooling water pressure(jacket cooling line)
0.15 0.25/ 0.39
(1.5 2.5/ 4.0)
Values marked with are per-
missible cooling water pres-
sure of central cooling system
when the pressurized water
inlet pressure or tank head
pressure are imposed
Cooling water pressure(cooler cooling line)
0.15 0.25/ 0.39
(1.5 2.5/ 4.0)
Starting air
pressure
Starting air tank 2.94(30) Lower limit:1.18(12)
After decompression 0.69 0.98(7 10) At the air motor inlet
Cooling water engine outlet temperature
K( )
358 4(85 4) At the rated output
Cooling water air cooler inlet temperature Below311(below38)
Lub.oil engine inlet temperature(cooler
outlet)
323 338(50 65)
Exhaust temperature(at each cylinder out-
let)

Trial.
Exh.gas turbocharger inlet temp.

Trial.
S
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e
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A
B
Adjust B after
setting it to zero
P
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e
2006.12.15R (Volume:2pages)
3.TABLE OF ENGINE STANDARD ADJUSTMENTS
3-2
3-3. Protective Device Setting Values
As for an asterisk(*), for equipment of each item varies as depended on the specification, refer to the Final
Document.
3-4. Holding Volumes of Lubricating Oil and Cooling Water
As for an asterisk(*), refer to the Final Document as the volume may vary according to the specification.
Item Unit Alarm Setting Value Emer.Stop Setting Value
Lub.oil engine inlet pressure
MPa(kgf/cm
2
)
0.34(3.5) 0.29(3.0)
Lub.oil turbocharger inlet pressure 0.25(2.5) ---
Cooling water engine outlet tem-
perature
K( ) 368(95) 373(100)
Rotational overspeed min
-1
(rmp)
115 120% of the rated
speed
* Lub.oil priming pressure
MPa(kgf/cm
2
)
0.02(0.2) ---
* Differential pressure(lub.oil
strainer)
0.09(0.9) ---
* Differential pressure(fuel.oil filter) 0.09(0.9) ---
* Starting air pressure 0.65(6.6) ---
* Control air pressure 0.65(6.6) ---
* Cooling water pressure(jacket
cooling line)
0.13(1.3) ---
* Cooling water pressure(cooler
cooling line)
0.13(1.3) ---
* Lub.oil engine inlet(cooler outlet)
temperature
K( ) 348(75) ---
[Unit: Itr.]
Item Holding Volume Remarks
Engine(incl.inside the cooler, strainer &
piping)
35
Lub.oil sump(common bed tank) * more than 1.0l/ps
* Governor
Type NZ61, RHD 1.3
Type PSG 2.0
Cylinder jacket(fresh water) 75
Cooler 25
L
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b
r
i
c
a
t
i
n
g

O
i
l
C
o
o
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i
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g

w
a
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e
r
1998.5.29R
4.OPERATION
4-1
(Operational Preparation)
4. OPERATION
During operation, the diesel engine runs at a high speed. Also, some parts of the engine are hot, and
the compressed air and such pressurized fluids as oil and water are flowing inside it. Therefore, thor-
oughly read the safety precautions before operation, maintenance and inspection to handle the
engine properly not to cause any accidents.
Chapter0, Section 3. Precautions on Safety
4-1. Operational Preparation
Before the initial start of the engine after its installation or before its restart after its overhaul servicing
or a long-term stoppage, sufficiently perform the following inspection and operation preparation in
addition to daily inspection and operational preparation, and make sure there is no abnormality and
the operational preparation has completed.
(1) Make sure no part nor tool has been left in the crankcase.
(2) Check for a part not tightened yet.
(3) If you have disassembled the valve mechanism, check the suction/exhaust valve head clearance.
Chapter 6, 6-3-6. Adjustment of Suc./Exh. Valve Head Clearance
(4) Operate the lubricating oil priming pump, and open the pressure indicator cocks of all the cylinders.
While turning the flywheel, make sure the lubricating oil is dropping from each part of the valve
rocker arm shafts, piston pins, crank pins, main sure bearings and swing arms.
(5) Bleed the air from the lubricating oil strainer.
(6) Bleed the air from the fuel oil filter and inlet pipe of fuel injection pump.
(7) Manually lubricate the governor linkage, and make sure it moves smoothly.
[ Procedures for turning the flywheel ]
Be careful not to allow your body to make contact with a moving part while turning the flywheel.
(Never put you hand into the crankcase.)
(Volume:18pages)
4.OPERATION
4-2
2001.6.15R
Turn the flywheel by the following procedures:
Turning Gear Device - - - - - - - - Operational spec.
(1) Remove the lock bar, loosen the stopper lock bolt and slightly move the stopper.
(2) Press the turning gear shaft down to the GEAR IN position.
(3) Fit the stopper into the groove B of the gear shaft, and then tighten the stopper lock bolt.
(4) Attach the socket and ratchet handle for turning to the shaft, and then turn the flywheel.
(5) When the turning operation has completed, return the turning gear shaft to the GEAR OUT position.
Then, fit the stopper into the groove A , and tighten the stopper lock bolt.
(6) Attach the lock bar.
Unless the turning gear is the GEAR OUT position, the turning gear engagement/disengagement
switch actures to disable starting. (optional spec)
Drawing 4-1. Turning gear device (Optional spec.)
4-1-1. Lubricating Oil System
The piping parts of lubricating oil system are banded with yellow coating.
1) Inspection and oil supply of lubricating oil sump
(1) Open the drain valve, cock or plug of the following oil sumps and devices; and check the drain.
Supply the lubricating oil to the upper limit of oil level gauge or dipstick in each oil sump;
Engine oil pan or common bed (lubricating system oil sump)
Governor oil sump
Lubricating oil cooler
Lubricating oil strainer
(2) Check the properties of lubricating oil; and if it is considerably contaminated of deteriorated, change it.
Chapter 3. Table of Engine Standard Adjustment
Chapter 5, 5-2-2. Control on Lub. Oil
Look Bar
Look Bar
Flywheel
Turning Gear
GEAR IN
Pos.
GEAR
OUT
Pos.
Turning Gear Shaft
Stopper
Stopper Lock Bolt
Micro Switch
A
B
4.OPERATION
4-3
Drawing 4-2. Draining&Air Bleeding Points on Non-operating Side Drawing 4-2. Draining & Air Bleeding Points
Oil Supplying Points on Operating Side
Hand Lubricating Points
Manually lubricate the governor link and control devices (circled portions)
Drawing 4-4. Governor Device
Lub. Oil Cooler
Lub. Oil Strainer
Air Vent Valve
Air Vent Plug
Chang-over Cock
Drain Plug
Drain Plug
Air Vent Plug
Lub. Oil Strainer
for turbocharger
Drain Plug
1st Lever Shaft
Start/Stop Lever Connector
Control Lever
for Gov. output
Governor
Drain Plug
Oil Level Gauge
Remove the top cover
and supply oil to 2 to
3 mm above the cen-
ter of oil level gauge.
Lub. Oil Dipstic
Lub. Oil Filler System oil sump
Drawing 4-5. Lub. System Oil
1999.7.2R
4.OPERATION
4-4
(Fuel Oil System)
2) Priming of lubricating oil
This engine employs the continuous priming system using a motor-operated pump.
Keep the control power supply for the motor-operated priming pump of this engine switched ON
always.
Switch OFF the said power supply in a long-term stoppage of the ship and in a rest and maintenance
servicing of the power installation.
After priming has stopped for two hours or longer, perform priming for about 20 minutes or longer.
Priming pressure: 0.02 0.20MPa (0.2 2.0kgf/cm
2
)
3) Air Bleeding of Lub. Oil Cooler
If any of the following items arises, start the engine after bleeding air from the lub. oil cooler, operate
the priming pump.
After priming has stopped for two hours or longer.
After disassembling & cleaning the lub. oil strainer.
After changing the lub. oil or disassembling the piping parts of lubricating oil system.
Air Bleeding Procedures
(1) Operate the priming pump.
(2) Open the air bleed valve of the lub. oil cooler.
(3) Discharge the air, and then close the air bleed valve.
If you cannot operate the motor-operated priming pump, perform air running for about 3 seconds
repeatedly five times.
After starting the engine should be executed the air venting again.
4-1-2. Fuel Oil System
The piping parts of fuel oil system are banded with red coating.
(1) Drain the fuel oil tank and fuel oil filter.
(2) Supply the fuel oil into the fuel oil tank, and check the fuel oil. Then, open or close each valve accord-
ing to the operation conditions.
(3) You use an engine of marine diesel oil (M.F.O) start/stop specifications, turn on the heater for the
heavy fuel oil (H.F.O.) pipe line, and continue heating the H.F.O. until its viscosity becomes proper.
4-5-1. M.D.O. CHANGE OVER
If you use an engine of heavy fuel oil (H.F.O.) start/stop specifications, make sure the fuel oil temper-
ature (viscosity) at the engine inlet is proper.
4-5-2. H.F.O. DIRECT START
Chapter 5, 5-1-3. Properties of Fuel Oil at the Engine Inlet
2009.2.25R
4.OPERATION
4-5
(4) Bleeding air from oil system
After engine installation, long-term stoppage or overhaul of the engine, bleed air from the fuel oil sys-
tem by the following procedures:
Open the bypass valve of fuel feed pump.
(Fully turn the bypass valve handle counterclockwise)
Open the air bleed cock of fuel oil filter to bleed air.
Drawing 4-6 Air Bleeding Points on Frontal Side
Loosen the air bleed plugs on the fuel oil pipe mount of each fuel injection pump to bleed air.
Drawing 4-7 Air Bleeding Points on Operating Side
Bleed the air from each fuel injection pump by the following procedures:
Set the start/stop lever in the RUN position, and push the rack of fuel injection pump to
the injection volume increase direction.
Attach the priming tools to the pump tappet while the plunger of fuel injection pump is at the
lowermost position.
8
7
6
5
4
9
2
3
1
By-pass Valve
Clockwise for close
Name Item
Fuel Feed Pump
Press Regulat. Valve
By-pass Handle
Chang-over Cock
Fuel Filter NO.2
Air Bleed Cock
Air Bleed Plug
Fuel Injection Pump
Drain Cock
1
2
3
4
5
6
7
8
9
Air Bleed Plug
(Fuel Oil System)
4.OPERATION
4-6
Drawing 4-8 Priming Procedures
Move up and down the priming lever until you feel a strong resistance.
Turn the flywheel to bleed the air from all of the cylinders.
Close the bypass valve.
(Fully turn the bypass valve handle clockwise.)
Fuel Oil Seal Pot Servicing Procedures (for Engine Using H.F.O.)
Seal pots are equipped to the mount for fuel oil pressure gauge and that for the fuel oil differential pressure
indicator (optional) of an engine using the heavy fuel oil (equivalent to 1,500-sec. or higher fuel oil).
Drawing 4-9 Seal Pot Servicing Procedures
No. Exclusive Tool Description Part No.
Priming lever 146673-92920
Lever support 146673-92930

Operate
Tappet
Fuel Pressure Gauge
Seal Pot
Pressure
Transmitter
Seal Pot
Differential Pressure
Indicator
(Fuel Oil System)
2002.5.15R
4.OPERATION
4-7
(1) Remove the filler plug and the air vent plug .
(2) Pour ethylene glycol from the filler until it overflow from the air vent plug.
(3) When the seal pot is filled with ethylene glycol, securely tighten the plugs & .
(4) Remove the plug , and pour ethylene glycol from the filler. When the seal pot is filled with ethylene
glycol, tighten the plug.
(5) Periodically (about every two months) loosen the plug and plug , and check if the fuel oil does not
overflow.
4-1-3. Cooling Water System
The piping parts of cooling water system are banded with blue coating.
(1) Inspect the cooling water tank, and check whether the cooling water is not contaminated. If the cooling
water is considerably, change it.
(2) Supply the cooling water to the upper limit of water level gauge, and add a proper amount of rust
inhibitor.
Chapter 5, 5-3-2. Brands of Rust Inhibitor & Adding Quantity
(3) Open and close each valve of the cooling water pipe system according to the operation conditions.
(4) If you use an engine of heavy fuel oil (H.F.O.) start/stop specifications, heat the cooling water in the
cylinder jacket side to 65 to 75 .
When you have replaced the cylinder liner or drawn it out for servicing, remove the cylinder side
cover and make sure no water leaks inside cylinder.
4-1-4. Boost Air System
Open the drain cocks of the following points to drain them.
Drawing 4-10 Boost Air System Draining Points on Non-operating Side
Open
(Cooling Water System & Boost Air)
2002.5.15R
4.OPERATION
4-8
(Starting & Control Air System / Starting)
2002.5.15R
4-1-5. Starting Air System
The piping parts of fuel oil system are banded with white coating.
(1) Drain the starting air reservoir.
(2) Make sure that the pneumatic pressure in the air reservoir is high enough to start the engine (2.2
MPa{22kgf/cm
2
} or higher).
4-1-6. Control and Protective Devices
(1) Move the start/stop lever from the RUN position to the STOP position and vice versa, and make sure
the rack of fuel injection pump, 1st lever shaft of governor link and connector move smoothly.
(2) Check for excessive play of connector pin.
(3) Set the power switch of protective and alarm devices to the ON position.
Unless the power switch is set in the ON position, the protective and alarm devices do not actuate.
4-2. Starting
This engine is started by an air motor.
Press the START switch. Then, the pilot air solenoid valve directly attached to the air motor will open on
the battery power to start the engine.
During start operation, do not bring your face close to the air motor. Dust adhered at the exhaust port
of air motor may enter your eye, resulting in injury.
Before the initial start of the engine after its installation of before its start after its overhaul or long-term
stoppage, perform air running by the following procedures, and make sure there is no abnormality.
Then, start the engine by the control panel on the engine side. If a large amount of fuel oil, cooling
water or lubricating oil should be entrapped in cylinders, "water hammering" may occur.
Set the ENGINE/REMOTE operation selector switch in the ENGINE position.
Open the pressure indicator cocks of all the cylinders.
Set the start/stop lever in the STOP position.
Hold the START switch pressing for 2 to 3 seconds to effect air running.
1) Starting operation procedures
Start the engine by the following procedures.
(1) Make sure the turning gear is it the GEAR OUT position.
(2) Make sure the pressure indicator cock is closed.
(3) Set the ENGINE/REMOTE operation selector switch to the ENGINE or REMOTE position correspont-
ing to the control panel to be selected.
4.OPERATION
4-9
(Starting)
2005.8.25R
(4) Set the start / stop lever in the RUN position.
(5) Make sure the pointer of speed control shaft of governor indicates the position of ordinary operation
(rated speed).
(6) Open the starting air reservoir valve and control air valve.
(7) Hold the START switch pressing for 2 to 3 seconds, and make sure of ignition. Only then release the
switch.
Drawing 4-11 Start Operating Procedures
Set it to the position in which the start/stop lever is fixed respectively in notch when you suit the start/
stop lever to the position of "RUN" or "STOP".
2) Corrective actions to be taken in starting failure
If the engine cannot be properly started, unburnt combustion gas in the flue may be ignited, resulting
in explosion. Therefore, perform air running to discharge the gas from the exhaust gas system before
attempting to restart the engine.
(1) Make sure the flywheel has completely stopped, and then press the START switch.
(2) If the battery power for the START switch has been exhausted (and in case of emergency), press the
manual button of air motor to start the engine.
Use starting control based on the manual button only in emergency because the air motor may rotate
excessively as the control module is not in operation in this case.
Drawing 4-12 Air Motor Manual Button
Speed Control Knob
(for Governor)
Speed Control Shaft
ENGINE/REMOTE
Operation Selector Switch
Control Air Valve
START Switch
Start/Stop Lever
Air Motor
Manual Button Pilot Air Solenoid Valve
4.OPERATION
4-10
(Running)
2002.5.15R
3) Checks to be made immediately after starting
Check the following items. If any abnormality is found, stop the engine and repair it.
(1) Value indicated by the pressure indicator on the gauge panel
(2) Leak from each piping
(3) Unusual sound and abnormal heat generation of each part
4-3. Running
During a run and immediately after the engine stop, never touch the following parts with bare hands.
Otherwise, you may get burnt.
Turbocharger, Exhaust pipe system, boost air pipe system
Flue and funnel
During a run, never touch any moving part. Otherwise, you may be caught in, resulting in injury.
Keep the control air valve opened during a run.
If you close it, the protective devices cannot actuate.
1) Initial Running-in Operation
To prevent initial abnormal wear of piston rings and cylinder liner, run the engine on marine diesel oil
(M.D.O) for the following period:
(1) For 10 to 20 hours after installation.
(2) For 10 to 20 hours after replacement of piston rings, piston or cylinder liner
2) Steady (Routine) Running
(1) Make sure the pressure of lubricating oil, cooling water and fuel oil has reached the specified value.
(2) Run the engine for about 10 minutes at the rated speed without load to warm it up.
(3) If the engine is used to drive a cargo pump or the like, which requires the control on rotation, run the
engine at the preset idling speed to warm it up.
The critical speed that may cause torsional vibration is within the normal rotation speed range, quickly
avoid it, and set the rotational speed to the rated speed.
4.OPERATION
4-11
(4) If you continue running the engine with a low load for longer than three hours, observe the following
load factors, otherwise combustion worsens and fouling of the combustion chamber, exhaust pipe,
turbocharger, etc. becomes heavy.
If fuel oil used is the marine diesel oil (M.D.O), run the engine at 15% or higher load factor.
If fuel oil used is the heavy fuel oil (H.F.O)
And if the (optional) boost air temperature controller which heats the boost air in a low load run is
equipped, run the engine at 15% or higher load factor.
But if the cooling water for the boost air cooler and lub. oil cooler is used jointly with the main
marine engine, run the engine at 20% or higher load factor.
If you want to run the engine at further lower load factor, change over the fuel oil to the M.D.O.
But if the cooling water for the air cooler and lub. oil cooler is sea water, run the engine at 25% or
higher load factor.
If you want to run the engine at further lower load factor, change over the fuel oil to the M.D.O.
(5) Boost air pressure regulating valve
To evade the surging generation of the supercharger when the high load is driven (vicinity of the load
of 100%), it equips the boost air pressure regulating valve (6N18AL-E V-type engine)
Drawing 4-12-2 Boost Air Press. Regulating Valve Installation position
Adjustment of boost air pressure regulating valve
* Adjust it in the state that opens from the state of all closes 180(state at shipment).
* Please turn the valve in an open direction and enlarge opening when the supercharger does surg-
ing by the change in the room temperature etc.
* Opening of the valve disc opens from all closes only to 540.
Boost Air Press. Regulating Valve
(Running)
2005.3.16R
4.OPERATION
4-12
Adjustment of Boost air temperature
(In the case of sea water cooling)
Adjust the boost air temperature to 40 to 60 , operating the cooling water bypass valve handle of
the boost air cooler.
As the bypass valve handle is set in the OPEN side, the cooling water bypassed, and the boost
air temperature rises.
Drawing 4-13 Sea Water By-pass Valve (Boost Air Cooler)
In the case of a high humidity, this is not abnormal although much drain may be produced as the
moisture in the air is condensed.
In this case, run the engine as the drain cock of the boost air cooler kept opened.
(6) If you use an engine of marine diesel oil (M.D.O.) start/stop specifications, observe the following
items:
If the load factor is less than 20% of the generator rated output, do not switch the fuel oil from the
M.D.O. to the heavy fuel oil (H.F.O.).
Make sure the H.F.O. at the engine inlet has been heated so that its viscosity becomes proper, and
then switch over the fuel oil from the M.D.O. to the H.F.O.
The load substantially fluctuates at the incoming and outgoing and loading and unloading of vessel.
For these operations, we recommend you to run the engine on the M.D.O.
Proper viscosity: 11 to 14 cSt (R.W.No.1 55 65 sec.)
4-5. Changeover to Heavy Fuel Operation and Heavy Fuel Operation (Appendices)
(7) Measure the running performance once a day and record the measurement data.
Chapter 6, 6-3-1. Measurement of Running Performance
By-pass Valve
Open
Drain Cock
Close
(Running)
2009.2.25R
4.OPERATION
4-13
(Stopping)
4-4. Stopping
4-4-1. Stopping in Normal Running
Except in case of emergency, stop the engine by the following procedures:
1) Preparation of stopping
(1) If you use an engine of marine diesel oil (M.D.O.) start/stop specifications, switch over the fuel oil from
the heavy fuel oil (H.D.O.) to the M.D.O. to prevent the H.F.O. from being stagnant inside the fuel oil
pipes, fuel oil filter, fuel injection pumps when stopping the engine.
As the reference, continue running the engine on the marine diesel oil (M.D.O.) for 20 to 30 minutes
before stopping the engine. However, since the required time depends upon the load applied when
the fuel oil is switched over and the capacity of pipes in the vessel, consult the dockyard where the
engine has been installed.
(2) Shut off the load, and then continue running the engine without load for about 10 minutes.
2) Stopping operation
(1) Set the start/stop lever in the STOP position.
If you use the engine of the remote start/stop specifications, press the STOP switch.
(2) Run the lubricating oil priming pump
(3) Open the pressure indicator cock, and perform air running to discharge the as from the combustion
chambers.
(4) Open or close the valves of each system according to the stopping conditions.
When the cooling water may be frozen under cold weather, or before a long term stoppage, drain the
cooling water from the cylinder jacket side and cooler side.
4-4-2. Emergency Stop
If any of the following problems arises, immediately set the start/stop lever in the STOP position to
stop the engine.
(1) Any of the following alarms has been issued.
Expressive pressure drop of lub. oil
Expressive temperature rise of lub.oil
Expressive tempera rise of cooling water
Overspeed
(2) An unusual sound has been made.
(3) Heat has generated unusually from a part
(4) Smoke is issued from a bearing or any other moving part.
(5) A pipe of fuel oil, lub. oil or cooling water system has been broken.
(6) The supply of cooling water has stopped, and it is impossible to supply it immediately.
(7) A setscrew or bolt of a moving part is loose or broken.
(8) Moisture is mixed in the lubricating oil.
(9) The boost air pressure has dropped, and the exhaust temperature has excessively risen.
(10) The rack of fuel injection pump has stuck.
(11) The exhaust temperature at individual cylinder outlet has dropped 40 less than the mean exhaust
temperature at each cylinder outlet, misfiring is often the cause of wrong influence on the torsional
vibration.
If the engine is not stopped by setting the start/stop lever in the STOP position or pressing the STOP
switch, close the fuel oil inlet valve.
2009.2.25R
4.OPERATION
4-14
4-4-3. Disposal After an Emergency Stop
When repairing the engine or investigating the cause of problem, observe the following items:
Do not open the side cover of crankcase for at least 10 minutes after having stopped the engine.
Entry of fresh air into the engine may cause ignition of oil mist, resulting in explosion.
If you have stopped the engine while it is running on the heavy fuel oil (H.F.O.), immediately dis-
charger the H.F.O. from the fuel oil pipes, fuel oil filter and fuel injection pumps, and displace them
with marine diesel oil (M.D.O.).
If the residual H.F.O. is cooled and its viscosity rises, it becomes impossible to restart the engine.
(1) Set the fuel oil changeover valves at the engine inlet and outlet to the marine diesel oil (M.D.O.)
position.
(2) Open the bypass valve of fuel feed pump.
(3) Open the drain cock of fuel oil filter and drain valve of fuel oil main pipe.
(4) Turn the flywheel to discharge the H.F.O. from the fuel injection pipes and fuel injection valves. (Set
the start/stop lever in the RUN position, and turn the flywheel under the fuel injection status.)
Drawing 4-14 H.F.O. Discharging Points
Fuel Oil
Discharg Valve
OPEN
Drain Cock
Fuel Oil Filter
Fuel Injection Pump
Normal CLOSE
Discharg OPEN
(Disposal After an Emergency Stop)
2005.3.16R
4.OPERATION
4-15
4-5. Changeover to Heavy Fuel Operation and Heavy fuel Operation (Appendices)
Pre-treatment
Thoroughly clean the heavy fuel in the pre-treatment stage.
(1) Starting
Start the engine on M.D.O. and continue M.D.O. operation for more than 15 minutes.
(2) Changeover to heavy fuel operation
Heat the heavy fuel oil and check that the fuel oil in the circulating line has the specified viscosity (11 ~
14 mm
2
/s at eng. inlet) and pressure (this is necessary to prevent clogging of the fuel strainer and
excessive pressure rise in the fuel injection pipe).
After checking that the temperature and pressure of each engine part is within the specified range,
changeover to heavy fuel operation with the load more than 20%.
(3) Heavy fuel operation
During heavy fuel operation, check that the fuel oil viscosity (or temperature) and pressure are within
the specified range.
(4) Stopping
Change from heavy fuel operation to M.D.O. operation.
(Note) Time depends on the load at switching (more than 20%) and onboard piping capacity.
Open H.F.O. outlet valve
Close M.D.O. outlet valve
Open H.F.O. inlet valve
Close M.D.O. inlet valve
H.F.O. changeover complete
019124-01E
Air vent from the strainer
Open M.D.O. inlet valve
Close H.F.O. inlet valve
Leave in this stage for 2 to 3 minutes, and return the
H.F.O. remaining in the main pipe to the H.F.O. tank.
Depending on the length of the inboard piping,
the waiting time may be longer.
Open M.D.O. outlet valve
Close H.F.O. outlet valuve
019125-01E
Run with M.D.O. for 20 minutes (flushing) (Note)
Stop the engine
(M.D.O. CHANGE OVER)
2009.2.25R
4.OPERATION
4-16
4-5-2. H.F.O. DIRECT START
(1) Starting and heavy fuel operation
During engine standby period
Heat and circulate the heavy fuel oil to obtain the viscosity of 11 ~ 14 mm
2
/s at the engine inlet.
Heat the engine, circulating the jacket cooling water at a temperature of 65 ~ 70 .
After checking the above conditions, start the engine.
(2) Stopping
Even after stopping the engine, keep heating the fuel oil to the specified viscosity and circulating it
(when re-starting the engine, make sure that the above engine standby conditions concerning heavy
fuel oil and jacket cooling fresh water are satisfied at least two hours in advance of re-starting).
When stopping the engine at long term period, change to M.D.O. operation before shutting down,
and be sure to completely replace all the heavy fuel oil in the fuel oil piping with M.D.O.
That if the temperature of the fuel oil drops below the pour point while the engine is stopped, it will not
be able to re-circulate heated fuel oil.
(3) Others
When the engine is stopped in emergencies or for other reasons, remove the heavy fuel oil which
remains in the fuel piping, and prepare the engine for re-starting on M.D.O.
For routine maintenance, inspection and servicing, please refer to the engine's operation manual.
(H.FO. DIRECT START)
2009.2.25R
4.OPERATION
4-17
4-6. Cleaning the turbine with water of RH..3 type turbochargers
(for auxiliary engine)
1) General
The dirt deposit on the turbine side can be reduced by periodical water cleaning.
The Water Cleaning should be done before deposit is not so heavy.
Cleaning at heavy deposits on turbine may cause great imbalance of the turbine rotor and damage to
the bearing parts. Strictly observe the cleaning interval.
2) Principle of cleaning
Fresh water below 60 is injected into exhaust pipes before turbocharger.
The cleaning effect is based upon the mechanical action of the impinging water droplets, and on the
water solubility of the deposits. So the water quantity and the exhaust gas temperature before turbo-
chargers when cleaning are determined for a part of water not to evaporate. Most of injected water
is evaporated or exhausted out, but the remain must be drained from exhaust pipe.
3) Installation
Refer the appendixes (Drawing 4-15).
A nickel series seizure inhibitor should be applied to the threaded parts of the needle valve and lock
nut.
Drawing 4-15 Installation
4) Cleaning procedure
(1) Cleaning interval
Cleaning should be done every 150 ~ 200hrs operation.
This period may change according to the dirt.
(2) Engine operation
Cleaning must be done at the engine output of 300 ~ 350 gas temperature, at the turbine inlet
(When it is unacceptable, without load operation at the rated speed) after keep running more than
20 minutes.
Fresh Water
Drain
Valve V2
Valve V1
Valve V3
Injection nozzle
Pressure gauge
030356-00E
2009.6.5R
4.OPERATION
4-18
(3) Cleaning procedure
At first close the valve V1 and V2.
Connect the water supply line to the water inlet pipe.
Open the valve V3.
Check whether the drain hole is not closed by carbon.
Open the valve V1, and then slowly open the valve V2 for 30 seconds.
"the valve V1 opening: about 2 turns"
The injection of water must be continued for 5 ~ 7 minutes.
Adjust the water pressure according to Table-1.
The index of water pressure refers to a value existing during water feeding.
Table-1
While injecting water, the condition of draining water from the valve V3 must be confirmed.
In case drain does not come yet after 5 minutes, raise water pressure more than 0.02 ~ 0.05MPa .
However drain does not come yet, injection of water must not be continued more than 7 minutes.
And then finish cleaning.
A drain pipe might be clogged due to the accumulation of the carbon. Check it regularly.
Close slowly the valve V1.
Close the valve V2.
After draining is stopped, close the valve V3.
After the cleaning, disconnect the water supply line in order to prevent any accidents.
(4) Water quantity
Fresh water used for cleaning. (Less than 60 )
(5) Drying up after water cleaning
In order to prevent water hammering, Keep running the engine for certain hours to dry up.
(More than 24 hours recommended.)
In the case where the drying run is insufficient, there is the possibility that water drops flow backward
to the engine side after it has stopped, causing corrosion of the turbine casing and the combustion
chamber or the "water hammering" trouble when starting the engine.
(6) The engine stops during dryness operation
The engine stops during dryness operation, have the drain valve V3 of kept opened so that residual
water can be discharged from the flue.
Make drain valve (V3) "close" after the maintenance check completion, and resume dryness opera-
tion.
(7) Engine performance after cleaning
Measure the engine performance (exhaust gas temperature after engine, air pressure after turbo-
charger) and check the cleaning effect after water cleaning.
If pressure or temperature does not change, cleaning may be repeated 2 or 3 times, keep an interval
for more than 30 minutes.
There is no change in performance even repeating injection, which causes the deposit to be very
heavy and hard. In this case the turbocharger should be dismantled for cleaning.
Water Pressure (MPa)
0.05 ~ 0.07
2009.6.5R
5.FUEL OIL, LUB. OIL & COOLING WATER
5-1
5. FUEL OIL, LUB. OIL & COOLING WATER
5-1. Fuel Oil
The properties of fuel oil applicable to this engine are shown in the following table.
The properties of fuel oil are uncertain and broadly ranged; thus they affect such factors as a smooth run of
the engine, maintenance interval and service life of parts. Consequently, it might be necessary to change
the specifications of engine or add attachment in accordance with the applied fuel oil.
5-1-1. Quality Criteria of Fuel Oil
Note: M.D.O. = marine diesel oil; I.F.O. = intermediate fuel oil
" Use HFO with the CCAI, (an ignitability index), below 850 as an standard. (However, please note that the
said value was estimated from the past operation data and that the value can vary depending on the future
fuel oil quality.) The use of HFO with CCAI exceeding 850 will cause faulty combustion and aggravate
exhaust color. If such use is inevitable, raise the intake air temperature. This will improve combustion to
an extent. However, raise the intake air temperature carefully in relation with the exhaust temperature,
since this will affect the exhaust temperature and other engine performance."
What is CCAI?
CCAI stands for Calculation Carbon Aromaticity Index, which shows an ignitability index.
The index, in consideration of the relation between aromatic compound content in fuel oil and the
ignitability is used to obtain the aromaticity degree in relation with the fuel oil properties. The larger
the CCAI value, the larger the firing delay for inferior ignitability. In this case, the HFO direct starting
is not possible or exhaust color is aggravated due to faulty combustion.
Direct burning fuel oil
Quality Criteria
--- 200sec.Oil 1,500sec.Oil 3,500sec.Oil 7,000sec.Oil
Viscosity
at 50 cSt 3 8 < 30 < 180 < 380 < 700
R.W.No.1 at 100F sec. 37 58 < 200 < 1500 < 3500 < 7000
Property
critical
value
Specific gravity at
15/4
< 0.86 < 0.991 < 0.991 < 0.991 < 0.991
Flash point

> 60 > 60 > 60 > 60 > 60
Residual carbon mass.% < 0.7 < 10 < 15 < 18 < 22
Sulfur content mass.% < 1.0 < 3.5 < 5 < 5 < 5
Ash content mass.% --- < 0.10 < 0.10 < 0.15 < 0.20
Moisture content vol.% < 0.1 < 0.5 < 1.0 < 1.0 < 1.0
Vanadium ppm --- < 150 < 300 < 500 < 600
Sodium ppm --- < 30 < 40 < 100 < 200
Aluminum ppm --- < 30 < 30 < 30 < 30
Diesel index
(Cetane no. of
> 45)
> 30 > 25 > 20 > 15
Quality criteria equivalent
fuel oil
ISO DBMorDMA RMB10 RME25 RMG35 RMH55
CIMAC --- CIMAC B10 CIMAC E25 CIMAC G35 CIMAC H55
BSI --- (M4) (M6) (M7) M9
JIS M.D.O I.F.O H.F.O.(heavy fuel oil)
2008.3.13R
(Fuel Oil)
(Volume:12pages)
5-2
5-1-2. Quality Criteria of Blended Fuel Oil
In the case of using a highly viscose fuel oil by blending with marine diesel oil to lower the viscosity of fuel
oil, in addition to the case of direct burning of fuel oil set forth above for its pretreatment, apply the blending
ratio shown in the following table based on the quality criteria on the blended fuel oil, not based on the vis-
cosity criteria.
When blending fuel oil of different production origins, sludge may be separated out, resulting in clog-
ging of fuel oil filters and sticking of fuel injection pumps and fuel injection valves. Pay your attention
to this regard.
Note: M.D.O. = marine diesel oil; H.F.O. = heavy fuel oil
Viscosity after blending: 5-1-6. How to Find out the Viscosity of Blended Oil
5-1-3. Properties of Fuel Oil at the Engine Inlet
Impurities contained in the heavy fuel oil (H.F.O.) may cause fuel injection pumps and fuel injection valves
to be damaged, cylinder liners to be excessively worn and exhaust valves and valve seats to be deterio-
rated. Therefore, raise the cleaning effect of pretreatment system to the maximum extent, and also supply
the fuel oil heated to have the proper pressure and viscosity.
Residual oil of a catalytic cracking refining device is sometimes used for industrial low-cost, high-vis-
cosity fuel oil. In this residual oil, there remain fine particles of silica and alumina that are catalysts for
this device.
A low-cost, high-viscosity fuel oil which uses there bases will cause abnormal wear of piston rings,
cylinder lines, fuel injection pumps, fuel injection valves, etc.
Therefore, use a low-cost, high-viscosity fuel oil treated of content less than 0.03 wt. % of ash, mini-
mum of silicon and aluminum and removed of all particles which exceed 3 5 in size, utilizing the
F.O. treating apparatus.
Incidentally, the moisture content should be kept at less than 0.2 vol. %.
(1) Recommend properties of heavy fuel oil (H.F.O.) at engine inlet
Blended fuel oil 200-sec. oil equivalent 1,500-sec. oil equivalent 3,500-sec. oil equivalent
Quality criteria on
direct burning
equivalent fuel oil
ISO RMB10 RME25 RMG35
CIMAC CIMAC B10 CIMAC E25 CIMAC G35
BSI (M4) (M6) (M7)
Blending ratio(%)
M.D.O.: H.F.O.(1,500-sec.oil)
60 : 40
70 : 30
40 : 60
60 : 40
30 : 70
Moisture content Less than 0.2 vol.%
Content of solid particles Less than 20 ppm
Size of FFC catalytic particle Less than 5
(Fuel Oil)
2009.2.25R
5-3
(2) Recommended viscosity and pressure of heavy fuel oil (H.F.O.) at engine inlet
Heating temperature: 5-1-5. How to Find out the Heavy Fuel Oil Heating Temperature
5-1-4 Characteristics of Heavy Fuel Oil and Influence on Engines
1) VISCOSITY
Viscosity and the viscosity index fluctuate widely in case of heavy fuel oil. Accordingly, it is important to
control and maintain the proper viscosity level the engine requires to run normally.
2) SPECIFIC GRAVITY, ASPHALTENE qAND DIESEL INDEX
The higher the specific gravity of the fuel oil, the higher its asphaltene content. High asphaltene con-
tent of the fuel oil lowers the diesel index because of the higher level of high molecular aromatic hydro-
carbon. This lowers the ignition performance of the engine, and causes abnormal combustion.
To enhance the ignition performance, a higher compression-ratio, optimal-combustion chamber shape
and structure must be used in the engine. It is also necessary to heat the engine to the proper temper-
ature.
The quality of fuel oil pre-treatment gives large effect to the specific gravity. Accordingly, it is important
to make appropriate arrangement for the pre-treatment equipment and method.
3) VANADIUM
In general, high vanadium content fuel oil causes high temperature corrosion of the exhaust valve. To
prevent this, cooling of the exhaust valve face and the use of corrosion-resistant material are neces-
sary.
4) ALUMINA AND SILICA
Fine particles of alumina or silica catalyzers in the fluid catalytic cracking (FCC) fuel oil will cause
abnormal wear of the engine's sliding parts. The installation and handling of proper pre-treatment
equipment for the fuel oil is therefore extremely important. When using FCC fuel oil, it is necessary to
remove all particles which exceed 3 ~ 5m in size.
5) CARBON RESIDUE
Excessive carbon residue will usually accelerate the accumulation of combustion products in the com-
bustion chamber especially under low load operation, and such residue on the sliding parts of the
engine will result in excessive wear and excessive lubricating oil consumption.
To cope with this problem, the engine design must minimize the adverse effects of the combustion
products. Regarding wear, consideration of effective lubrication of the sliding parts and employment of
durable materials are necessary.
6) SULFUR
High sulfur content of the fuel oil causes low temperature corrosion of the combustion chamber. To
prevent this, the temperature of the combustion chamber must be kept at an appropriate level.
Fuel oil
Recommended Viscosity
at the Engine Inlet
Recommended Pressure
MPa (kgf/cm
2
)
200-sec. oil
11 14 cSt
(R.W. No.1 55 65 sec.)
0.20 0.25 (2.0 2.5)
1,500-sec. oil 0.40 0.45 (4.0 4.5)
3,500-sec. oil 0.45 0.50 (4.5 5.0)
7,000-sec. oil 0.65 0.70 (6.5 7.0)
M.D.O. 3 8 cSt 0.50 0.55 (5.0 5.5)
(Fuel Oil)
2009.2.25R
5-4
50000
1040
1020
1000
980
960
940
920
900
880
860
860
820
800
800
810
820
830
840
850
860
870
880
890
900
910
920
930
40000
5000
1000
400
100
50
30
20
10
5
4
3
2
1
200
V D CCAI
[ Example ]
Obtaining CCAI of HFO with the viscosity of 380cSt @ 50 and the density of 985 kg/m
3
@ 15 from the table above:
Draw a line from the viscosity (V) 380cSt to the density (D) 985 and extend the line to
CCAI column. The fuel oil CCAI in the present example is 846.
CCAI = D - 81 - 141 loglog (V + 0.85)
D : Density kg/m
3
@ 15 V : Viscosity mm
2
/S @ 50
Calculation of CCAI
The smaller CCAI,
the better firing
and combustion
performance.
The larger CCAI,
the inferior firing
performance.
This will cause
normal operation
to be hard.
017663-00E
2002.12.25R
(Fuel Oil)
5-5
5-1-5. How to Find out the Heavy Fuel Oil Heating Temperature
Example: In the case of finding out the heating temperature of 700 cSt (at 50 ) fuel oil
Find the intersecting point corresponding to viscosity of 700 cSt and temperature of 50 on a
line standing for viscosity-temperature relation of 700 cSt (at 50 ) fuel oil.
On this line , locate a point corresponding to the recommend viscosity at the engine inlet, and
then draw a perpendicular from this point to the axis of abscissa (x-axis).
The intersection of this perpendicular with the x-axis indicates the heating temperature required.
(In this case, the temperature is 150 .)
(1) Prepare a correct viscosity-temperature relation chart according to the properties of fuel oil existing
at the time of its delivery to you.
If the viscosity - temperature line corresponding to your applied fuel oil is not shown, enter the vis-
cosity and temperature of the applied fuel oil on the above chart, item from the intersecting point of
the entered data draw a line in parallel to the nearest drawn viscosity-temperature line, and find out
the heating temperature accordingly.
(2) Set the fuel heating temperature so that the fuel oil viscosity becomes 11 to 14 cSt (55 to 65 sec.) at
the engine inlet to allow some temperature drop in the piping system.
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017667-00E
(Fuel Oil)
2009.2.25R
5-6
5-1-6. How to Find out the Viscosity of Blended Oil
Example: In the case of finding out the viscosity of blending (R.W. No.1 at 100F) 7,000-sec. heavy fuel oil
(H.F.O.) with (R.W. No.1 at 100F) 40-sec. marine oil (M.D.O.) at the blending ratio of 70:30.
On the left y-axis (axis of ordinate) corresponding to 100 % H.F.O., locate the point A
corresponding to the viscosity (7,000 sec.) of H.F.O.; on the right y-axis corresponding to 100 %
M.D.O., the point B corresponding to the viscosity (40 sec.) of M.D.O. Now draw a straight line
K to link both located points.
Then, locate the point Y corresponding to the blending ratio of 70 % H.F.O. and 30 % M.D.O. on
the axis of abscissa (x-axis), and draw a perpendicular from the point Y to the drawn straight
line K , intersecting at the point C . Finally, draw a horizontal line from thus found intersecting
point C to the left y-axis to find out the viscosity of the blended oil. (In the case, the viscosity at
100F is about 550 sec.)
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017664-00E
(Fuel Oil)
2009.2.25R
5-7
5-2. Lubricating Oil
Selection of the proper lubricating oil is important for a diesel engine. In case of using an inappropriate lub.
oil, sticking of piston ring, seizure and early wear of piston, cylinder liners and bearings, etc. will occur.
Consequently, discreetly select the lubricating oil to be used.
5-2-1. Choosing the Lub. Oil
Depending on properties of fuel oil and conditions of usage of the engine, lub. oil to be selected varies.
Choose lub. oil API Service Grade CE or CD Class.
1) Viscosity
Use an oil shown in the below table.
2) Total Base Number (T.B.N.)
Select a lub. oil based on the values given in the following table for the base number against the sulfur
content including in the fuel used.
Lub. oil to be applied: 5-2-3. List of Lub. Oil Brands
(1) Avoid blended use of different brands.
(In the unavoidable case of blended use of different brands of lub, consult your lub. oil supplier.)
(2) If lub. oil of a high total base number (T.B.N.) is used when using fuel oil of a low sulfur content,
additive (calcium carbonate) of lub. oil sticks to the high-temperature area together with carbon
residue and causes adverse effects as mentioned below: For that reason, use the proper lub. oil.
Accumulation of the aforementioned deposits on the combustion chamber hinders sliding of piston
rings and may cause scuffing to the rings, cylinder liners, etc. Besides, they may cause bite-in and
blow-bye if intruded into exhaust valves.
Application
Viscosity
(SAE)
Specific
Gravity
Frash point
(Open
Type)
Pour Point
( )
Kinematic Viscosity(cSt)
Viscosity
Index
40 100
Marine aux-
iliary engine
30 0.89 > 230 < 10 105125 11 12.5 96 110
Marine aux-
iliary engine
Land use
engine
40 0.893 > 240 < 7.5 140155 1415.5 96 110
Fuel Oil Used
Sulfur Content
(wt. %)
Total Base
Number
(T.B.N.)
(mgKOH/g)
Redwood No.1
Viscosity
s(100F)
M.D.O. equivalent < 1 9 15
I.F.O. eq. 200-sec. < 3.5 16 26
H.F.O. eq.
1,500-sec
3,500-sec.
7,000-sec
< 5 30 42
(Lub. Oil)
2002.5.15R
5-8
5-2-2. Control on Lub. Oil
In case of handling the lubricating oil inside the engine immediately after an engine stop, be careful
not to get burnt.
Should there be a possibility of lubricating oil to get in your eyes or to stick to your skin during han-
dling of lubricating oil, wear protectors such as safety goggles and rubber gloves.
If lubricating oil get in your eyes or stick to your skin, it might cause inflammation. In such case,
flush an affected region with clean water, and then consult a physician, if necessary.
Method of disposing waste oil has been provided for in the law. Dispose of waste oil properly
according to the pertinent law. In case you dont know what to do, inquire of your supplier of lubri-
cationg oil about this matter, and dispose of waste oil accordingly.
1) Control Criteria
Conduct the property analysis of lub. oil used every 500 hours of engine run, and change or make up the
lub. oil as guided by control criteria set forth in the following table.
2) Oil Change Criteria
Since oil change criteria vary as depended on conditions of use of the engine, an instance of the criteria
may be set forth as follows although they could not fixed uniformly on base of the time used alone.
(1) Ask your lub. oil supplier to analyze the lub. oil being used and thus to determine whether the oil can
be further used continually or not.
Item Unit Control Criteria Critical Value of Usage
Flash point(PM method)

> 180 140
Change in viscosity cSt(40 ) Within new oil 15 % New oil 25 %
Moisture content vol.% < 0.1 0.2
n-pentane insoluble matter
(A method)
mass.% < 1.5 2.0
Toluene insoluble matter
(A method)
mass.% < 1.5 2.0
Difference between n-
pentane and toluene
insoluble matters
mass.% --- < 0.5
Total base number mgKOH/g
Meas. method
HCl
method
HClO
4
method
HCl
method
HClO
4
method
Fuel oil used
M.D.O. 3.0 6.0 1.0 4.0
200-sec. oil 5.0 10.0 3.0 7.0
1,500-sec. oil
12.0 18.0 10.0 15.0
3,500-sec. oil
7,000-sec. oil 12.0 18.0 10.0 15.0
(Lub. Oil)
2004.11.25R
5-9
Sample 500 cc of lub. oil at least from the drain plug of lub. oil strainer immediately after stopping the
engine for asking the analysis of lub. oil.
(2) Procuring a spot test kit to learn the remaining total base number, degree of contamination, cleanness
dispersing qualities of lub. oil used, etc. as a simple way of criteria, make the most of using such a
spot test kit.
(3) Should either of the aforementioned criteria be not possible, change the entire volume of lub. oil with
the new one at about 1,500 running hours in the case of constantly holding the oil volume of 1 ltr. /PS
by replenishing with the new oil.
5-2-3. List of Lub. Oil Brands
API Service Grade CD class or more /SAE 30 or 40.
Fuel Oil Spec.
Division
Marine diesel oil
M.D.O.
Intermediate fuel oil
I. F.O.=(R.W. No.1 at 100F)
200sec. Oil
Heavy fuel oil
H.F.O.=(R.W. No.1 at 100F)
1,500sec./3,500sec./7,000sec.Oil
Total Base
Number (T.B.N)
9 15 16 25 30 42
YANMAR
YANMAR MARINE
SUPER OIL 30, 40
--- ---
IDEMITSU
KOSAN
DAPHNE MARINE OIL SX30, SX40
DAPHNE MARINE OIL MV30, MV40
DAPHNE MARINE OIL SW30, SW40
DAPHNE MARINE OIL SA30, SA40
DAPHNE MARINE OIL SH40
EXXON MOBIL MOBIL GARD 312, 412
MOBIL GARD 312, 412
MOBIL GARD M330, M430
CASTROL
MCL 30, 40
CASTROL MHP 153, 154
SEAMAX EXTRA 30, 40
CASTROL TLX Plus 203, 204
Chevron
(Caltex, Texaco)
Delo 1000 Marine 30, 40
Taro 12 XD 30, 40
Taro 20 DP 30, 40
Taro 30 DP 30, 40
Taro 30 DP 30, 40
Taro 40 XL 30, 40
KYGNUS OIL KYGNUS MARINE DX 30, 40 KYGNUS MARINE DX 330, 340 ---
COSMO OIL COSMO MARINE SUPER 30, 40 COSMO MARINE 3025, 4025 COSMO MARINE 3040, 4040
SHELL GADINIA OIL 30, 40
ARGINA S OIL 30, 40
RIMULA FB OIL 30, 40
ARGINA T OIL 30, 40
ARGINA X OIL 30, 40
JAPAN
ENERGY
JOMO MARINE D13, 14 JOMO MARINE D23, 24 JOMO MARINE D33, 34
TOTAL
Lubmarine
DISOLA M3015, 4015
AURELIA XL 3030, 4030
AURELIA TI 3030, 4030
AURELIA XL 3040, 4040
AURELIA TI 3040, 4040
FUJI KOSAN FUKKOL MARINE 312, 412 FUKKOL MARINE 320, 420 FUKKOL MARINE 330, 430
BRITISH
PETROLEUM
BP ENERGOL DS3-153, 154 BP ENERGOL IC-HFX203, 204
BP ENERGOL IC-HFX303, 304
BP ENERGOL IC-HFX403, 404
NIPPON OIL MARINE T103, T104 MARINE T203, T204 MARINE T303, T304
(Lub. Oil)
2008.12.25R
5-10
2003.10.20R
(Cooling Water)
5-3. Cooling Water (Engine Jacket Water)
5-3-1. Criteria on Cooling Fresh Water
(1) Use pure water (distilled water) or tap water.
(2) Use the water having the properties shown in the following table.
5-3-2. Selection of and Control on Corrosion Inhibitor
(1) Add a corrosion inhibitor to cooling fresh water because use of fresh water causes a drop in strength
of parts and the cooling effect through corrosion of water chamber and adhering of scale.
(2) Select a corrosion inhibitor which does not have an adverse effect on parts of the cooling water sys-
tem because parts made of cast iron, carbon steel, brass and bronze, are used in the cooling water
system of an engine.
In the case where aluminum materials are used in the cooling water system, consult the supplier of
corrosion inhibitor because a kind of corrosion inhibitor to be used differs in this case.
As to the adding quantity of and concentration control on corrosion inhibitor and addition and han-
dling of supplementary adjuster, obey the criteria set by the supplier of corrosion inhibitor.
In the case where the concentration of corrosion inhibitor could not be controlled, annually change
the cooling water by the total volume.
Do not dump cooling water to which the corrosion inhibitor was added directly to the ocean or river.
Since the method of treating the waste liquor has been provided for in the law, such liquid has to
be treated according to instructions given by the supplier of corrosion inhibitor.
Do not mix different brands of corrosion inhibitor. (In the case where mixing of different brands of
corrosion inhibitor is unavoidable, consult the suppliers of corrosion inhibitor.
A corrosion inhibitor is chemical for industrial water treatment use; do not use it in the drinking
water line.
When handling, wear rubber gloves and gauze mask to avoid direct contact with hands or other
parts of the body.
If the chemical accidentally comes in contact with skin, eyes or mouth, wash out thoroughly with
fresh water. If the problem persists, consult a doctor.
Recommended Water Quality
pH 298 K (25 6.3 8.0
Total hardness (CaCO
3
) < 100 ppm
Chlorine ion (Cl
-
) concentration < 100 ppm
M alkalinity 30-100 ppm
Ammonium ion (NH
4
+
) conc. < 0.05 ppm
Sulfate ion (SO
4
- -
) concentration < 100 ppm
Evaporated residue < 400 ppm
Do not use hard water.
If hard water is used, scale adheres to
water chambers such as cylinder head and
cylinder water jackets and may cause an
overheat. Pay your particular attention to
this regard.
5-11
(3) Recommended brands of corrosion inhibitor
Brands of corrosion inhibitor applicable to the enclosed circuit specification of the cooling water system are
shown in the following table.
In the case where the cooling water system is of the enclosed circuit specification, consult the sup-
plier of corrosion inhibitor because some brands drop in the concentration of corrosion inhibitor early.
Notice a corrosion inhibitor which doubles as an anti-freeze has a low thermal conductivity and may
be overheated during a load running.
In the case where aluminum materials are in the cooling water system, use a brand of corrosion inhib-
itor asterisked above.
Brand Supplier Brand Supplier
Royal Caviruston Antirust
Yanmar Sangyo Co., Ltd. Diesel Guard NB
UNITOR & Taiho
Industries Co., Ltd
*YANMAR Royal Freeze
Polycrin I - 109
Kurita Water Industries Ltd.
Rocor NB Liquid
Polycrin I - 175 Nalcool 2000
NALCO Japan Co., Ltd. *Kurilex L - 501 *Nalfleet 9 - 111
Neos PN - 106S
Neos Co., Ltd.
Nalfleet 9 - 108
Neos PN - 106 Uniprot PC - 200
Nippon Yuka Kogyo Co., Ltd.
Hi-mol L - 10
Taiho Industries Co., Ltd.
Uniprot PC - 300
Hi-mol AM - 5 Shadan K Otsuka Chemical Co., Ltd.
*Olgard C-601 Organo Co., Ltd. Liquide WT ASHLAND JAPN CO., Ltd
2006.10.16R
(Cooling Water)
5-12
MEMO
6.MAINTENANCE CHECKING
6-1
6. MAINTENANCE CHECKING
6-1. Precautions in Maintenance Checking
To use an engine always in good order, checking is necessary periodically for trouble prevention. The
period of checking can not be fixed indiscriminately because it is influenced by application of the engine,
conditions of use, quality of fuel oil and lub. oil used, and daily handling circumstance.
The following tables of checking show the standard checking frequency. Perform the initial overhaul
servicing according to these checking tables. Then, based on the obtained checking (on wear corro-
sion, accumulation of carbon, accumulation of sludge and others), make the most economical check-
ing schedule suitable for your engine, and conform to the specified schedule from the second
checking.
As for the items whose checking frequency is shown by both the accumulated operation hours and
number of days, schedule the checking at the earlier timing.
6-2. Table of Periodical Checking
(1) For marine service engine
1) Table of Routine Maintenance Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Table 6-1.
2) Checking Table for Engine Using Marine Diesel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Table 6-2.
3) Checking Table for Engine Using Heavy Fuel Oil (R.W. No.1 at 100F 1,500 7,000-sec. Equivalent
Fuel Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Table 6-3.
(2) For land service and/or generator engine
In accordance with the Specifications of Checking & Servicing of Diesel Service Generating Set separately
stipulated.
6-3. Routine Maintenance Checking & Adjustment Procedures
6-3-1. Measurement of Running Performance
6-3-2. Measurement of Max. Combustion Pressure (Pmax)
6-3-3. Regulation of Fuel Injection Volume (Rack Scale)
6-3-4. Adjustment of Fuel Injection Timing
6-3-5. Checking of Fuel Injection Valve & Adjustment of Injection Pressure
6-3-6. Adjustment of Suc./Exh. Valve Head Clearance
6-3-7. Adjustment of Lub. Oil Pressure
6-3-8. Adjustment of Lub. Oil Temperature
6-3-9. Adjustment of Fuel. Oil Pressure
6-3-10. Checking of Cyl. Jacket Cooling Water Thermostatic Valve
6-3-11. Cleaning of Lub. Oil Bypass Strainer
6-3-12. Cleaning of Lub. Oil Strainer
6-3-13. Cleaning of Fuel. Oil Filter
6-3-14. Cleaning of Strainer Element
6-3-15. Washing of Turbocharger Blower
6-3-16. Maintenance of Pressure Gauge
6-3-17. Measurement of Crankshaft Deflection
6-3-18. Adjustment of Fuel. Injection Pump Pinion Lubricating Volume (for Engine Using H.F.O.)
6-3-19. Maintenance of Fuel. Oil Seal Pot (for Engine Using H.F.O.)
6-3-20. Checking & Replacement of Anticorrosive Zinc
2006.1.20R
(Precaution in Maintenance Checking)
(Volume:40pages)
6-2
Table 6-1. Table of Routine Maintenance checking
Note: An asterisk (*) refers to only for engine using heavy fuel oil (H.F.O.)
Checking Area
Nature of Work
Daily Weekly Monthly (or 300-500hrs.)
Starting air tank Pressure check Draining
Governor gear Gov. oil volume check
Checking & lubrication of
linkage system
F
u
e
l

O
i
l

S
y
s
t
e
m
Fuel feed pump
Check on leak from oil
seal
Fuel oil filter Draining Back-washing (blow-off) Overhaul cleaning
Fuel injection
Pump
Check on rack scale
position
*Check on pinion lubri-
cating Volume
Injection timing
adjust bolt
Check on looseness of
lock nuts
L
u
b
.

O
i
l

S
y
s
t
e
m
Common bed
(or oil pan)
Oil volume check
Lub. oil cleaning
The batch cleaning by
the purifier
Lub. oil property analysis
Lub. oil strainer Draining
Back-washing (blow-off)
* (2 3 days)
Overhaul cleaning
* (10 15 days)
Lub. oil bypass
strainer
--- Overhaul cleaning
Cooling water
pump
Check on leak from
mechanical seal
Turbocharger
Prefilter washing
Blower washing
Starting air motor
Check that electrical wir-
ing is fastend firmly.
Check that no air leaks
from the air pipe and the
joint.
I
n
s
t
r
u
m
e
n
t
Each pressure
gauge
Check on defective indi-
cation
Each thermom-
eter
Check on defective indi-
cation
Engine appearance
Check on looseness of
bolts & nuts
Check on leaks of vari-
ous parts
(cooling water, fuel oil,
lub. oil, boost air &
exhaust gas)
Each pipe system Leak check
2003.12.10R
(Routing Maintenance Checking)
6-3
Table 6-2. Checking Table for Engine Using Marine Diesel Oil (1/3)
An asterisk (*) given in the following tables refers to the timing of initial check after the initial start or
part replacement. Perform the check from the second time and onward at the ordinary frequency.
Div.
Part to Be
Checked
Nature of Service
Checking & Servicing
Frequency (hrs.)
3

m
o
.

o
r

1
,
0
0
0
1
,
5
0
0
6

m
o
.

o
r

2
,
0
0
0
2
,
5
0
0
1

y
r
.

o
r

4
,
0
0
0
5
,
0
0
0
2
3

y
r
.

o
r

8
,
0
0
0
1
0
,
0
0
0
5

y
r
.

o
r

1
6
,
0
0
0
2
0
,
0
0
0
C
y
l
i
n
d
e
r

h
e
a
d
Fuel injection
valve
Drawing-out check & adjustment 1,500 2,000 1st time:500800hrs
Cylinder head
Check & adjustment of the valve head clearance

Check of valve spring

Check disassembly & check of valve rotator

Disassembly, check & cleaning

Grinding of suc./exh. valve seat

Scale cleaning & hydraulic test of water chamber

Replacement of stem seal (Suc./Exh. Valve)
Check of cyl. head bolt tightening force

M
a
j
o
r

M
o
v
i
n
g

P
a
r
t
s
Piston
Drawing-out, cleaning, checking & measurement
of piston

Check & measurement of piston rings

Check & measurement of piston pin

Connecting
rod
Check & measurement of piston pin metal

Check & measurement of crank-pin metal

Check of connecting rod bolt tightening force

Change of connecting rod bolts 20,000 hrs.
Cyl. liner
Inner dia. checking, cleaning & measurement

Drawing-out, check & cleaning of water jacket
part

Crankshaft
Measurement of crank pin outer dia. & journal
Measurement & adjustment of deflection
Main bearing
Disassembly, metal checking & measurement

Check on tightening force of main bearing clamp-
ing bolts

Check on tightening force of side bolt

Camshaft
Check of cam & roller bearing

Disassembly & check of fuel pump tappet

Disassembly, check & measurement of swing arm

Drawing-out of camshaft & bearing check &
measurement

Timing gear
Check of tooth bearing & backlash

Disassembly of idle gear & check & measurement
of bearing

Check of idle gear mounted shaft tightening force

(Engine Using Marine Diesel Oil)
2009.3.24R
6-4
D
i
v
.
Part to Be
Checked
Nature of Service
Checking Servicing
Cycle (hrs.)
3

m
o
.

o
r

1
,
0
0
0
1
,
5
0
0
3

m
o
.

o
r

2
,
0
0
0
2
,
5
0
0
1

y
r
.

o
r

4
,
0
0
0
5
,
0
0
0
2
3

y
r
.

o
r

8
,
0
0
0
1
0
,
0
0
0
5

y
r
.

o
r

1
6
,
0
0
0
2
0
,
0
0
0
M
a
j
o
r

M
o
v
i
n
g

P
a
r
t
s
Fuel feed
pump, lub. oil
pump, & cold
water pump
driving
intermediate
gear.

Disassembly, check & measurement
of bearing

Check of gear mounted shaft tighten-
ing force

G
o
v
.

G
e
a
r
Governor
Change of hydraulic fluid

Disassembly & check

Governor driv-
ing gear
Disassembly & check of tooth bear-
ing & bearing

F
u
e
l

O
i
l

S
y
s
t
e
m
Fuel injection
pump
Check of injection timing

1st time: 300 - 500
Check of deflector & replacement

Disassembly, cleaning & check

Fuel feed
pump
Disassembly & check

Replacement of oil seal

F.O.control &
stop air piston
Replacement of o-ring

L
u
b
.

O
i
l

S
y
s
t
e
m
Lub. oil
Change (depended on results of
property analysis)

Lub. oil cooler
Disassembly, check, cleaning &
hydraulic test

Thermostatic
valve

Lub. oil pump

Disassembly & check of pres. reg.
valve & safety valve

Turbocharger
lub. oil
strainer
Change the element of lub. oil
strainer
1,000-
2,000
Change the element
When the lub. oil
pressure dropped by
0.3MPa(3kgf/cm
2
)
Lub.oil priming
motor pump
Bearing of motor

1st
time
2nd
&
sub-
seq
uent
2005.3.16R
6-5
D
i
v
.
Part to Be
Checked
Nature of Service
Checking Servicing
Cycle (hrs.)
3

m
o
.

o
r

1
,
0
0
0
1
,
5
0
0
3

m
o
.

o
r

2
,
0
0
0
2
,
5
0
0
1

y
r
.

o
r

4
,
0
0
0
5
,
0
0
0
2
3

y
r
.

o
r

8
,
0
0
0
1
0
,
0
0
0
5

y
r
.

o
r

1
6
,
0
0
0
2
0
,
0
0
0
C
o
o
l
i
n
g

W
a
t
e
r

S
y
s
t
e
m
Thermostatic
valve

Cooling water
pump

Replacement of mechanical seal

Fresh water
cooler
Disassembly, check, cleaning & hydrau-
lic test

Cooling water
(Fresh water)
Change (depended on results of prop-
erty analysis)

Sea water cool-
ing parts
Check of anticorrosive zinc & replace-
ment (Air cooler & Lub. oil cooler)

O
t
h
e
r
Turbocharger Disassembly & cleaning

Boost air cooler
lic test

Starting air
motor
Disassemble and clean the muffler ele-
ment. (Clean with neutral detergent.)

Remove the starting motor from the
engine and turn the pinion gear manu-
ally, check that it turns smoothly and it
emits no abnormal sound.
Disassembly, inspection, cleaning and

replacement of grease of moving parts.
replacement of o-ring, first reduction
gear bearing and special grease inside
the reduction gear.

replacement of o-ring, 1st & 2nd reduc-
tion gear bearings and special grease
inside the reduction gear.
Engine tachome-
ter
Calibration of indication

Alarm switch Actuation test

2002.5.15R
6-6
Table 6-3. Checking Table for Engine Using Heavy Fuel Oil (R.W. No.1 at 100F 1,500 7,000-sec. Equiv-
alent Fuel Oil) (1/3)
An asterisk (*) given in the following tables refers to the timing of initial check after the initial start or
part replacement. Perform the check from the second time and onward at the ordinary frequency.
Div.
Part to Be
Checked
Nature of Service
Checking & Servicing
Frequency (hrs.)
3

m
o
.

o
r

1
,
0
0
0
1
,
5
0
0
6

m
o
.

o
r

2
,
0
0
0
2
,
5
0
0
1

y
r
.

o
r

4
,
0
0
0
5
,
0
0
0
2
3

y
r
.

o
r

8
,
0
0
0
1
0
,
0
0
0
5

y
r
.

o
r

1
6
,
0
0
0
2
0
,
0
0
0
C
y
l
i
n
d
e
r

h
e
a
d
Fuel injection
valve
Drawing-out check & adjustment 1,500 2,000 1st time:500800hrs
Cylinder head
Check & adjustment of the valve head clearance

Check of valve spring

Check disassembly & check of valve rotator


Grinding of suc./exh. valve seat

Scale cleaning & hydraulic test of water chamber

Replacement of stem seal (Suc./Exh. Valve)
Check of cyl. head bolt tightening force

M
a
j
o
r

M
o
v
i
n
g

P
a
r
t
s
Piston
Drawing-out, cleaning, checking & measurement
of piston

Check & measurement of piston rings

Check & measurement of piston pin

Connecting
rod
Check & measurement of piston pin metal

Check & measurement of crank-pin metal

Check of connecting rod bolt tightening force

Change of connecting rod bolts 20,000 hrs.
Cyl. liner
Inner dia. checking, cleaning & measurement

Drawing-out, check & cleaning of water jacket
part

Crankshaft
Measurement of crank pin outer dia. & journal
Measurement & adjustment of deflection
Main bearing
Disassembly, metal checking & measurement

Check on tightening force of main bearing clamp-
ing bolts

Check on tightening force of side bolt

Camshaft
Check of cam & roller bearing

Disassembly & check of fuel pump tappet

Disassembly, check & measurement of swing arm

Drawing-out of camshaft & bearing check &
measurement

Timing gear

Disassembly of idle gear & check & measurement
of bearing

Check of idle gear mounted shaft tightening force

(Engine Using Heavy Fuel Oil)
2009.3.24R
6-7
D
i
v
.
Part to Be
Checked
Nature of Service
Checking Servicing
Cycle (hrs.)
3

m
o
.

o
r

1
,
0
0
0
1
,
5
0
0
3

m
o
.

o
r

2
,
0
0
0
2
,
5
0
0
1

y
r
.

o
r

4
,
0
0
0
5
,
0
0
0
2
3

y
r
.

o
r

8
,
0
0
0
1
0
,
0
0
0
5

y
r
.

o
r

1
6
,
0
0
0
2
0
,
0
0
0
M
a
j
o
r

M
o
v
i
n
g

P
a
r
t
s
Fuel feed
pump, lub. oil
pump, & cold
water pump
driving
intermediate
gear.

Disassembly, check & measure-
ment of bearing

Check of gear mounted shaft tighten-
ing force

G
o
v
.

G
e
a
r
Governor
Change of hydraulic fluid

Disassembly & check

Governor driv-
ing gear
Disassembly & check of tooth bear-
ing & bearing

F
u
e
l

O
i
l

S
y
s
t
e
m
Fuel injection
pump
Check of injection timing

1st time: 300 - 500
Check of deflector & replacement

Disassembly, cleaning & check

Fuel feed
pump
Disassembly & check

Replacement of oil seal

Pressure
gauge seal
pot
Check on filling of ethylene glycol

Change of ethylene glycol

Accumulator
Replacement of Accumulator (for
Fuel oil line: F.O. Main pipe & Pres-
sure regulating valve.)

optional part
F.O.control &
stop air piston
Replacement of o-ring

L
u
b
.

O
i
l

S
y
s
t
e
m
Lub. oil
Change (depended on results of
property analysis)

Lub. oil cooler
Disassembly, check cleaning, &
hydraulic test

Thermostatic
valve

Lub. oil pump

Disassembly & check of pres. reg.
valve & safety valve

Turbocharger
lub. oil
strainer
Change the element of lub. oil
strainer
1,000-
2,000
Change the element
When the lub. oil pres-
sure dropped by
0.3MPa(3kgf/cm
2
)
Lub.oil priming
motor pump
Bearing of motor

1st
time
2nd
&
sub-
seq
uent
2005.3.16R
6-8
D
i
v
.
Part to Be
Checked
Nature of Service
Checking Servicing
Cycle (hrs.)
3

m
o
.

o
r

1
,
0
0
0
1
,
5
0
0
3

m
o
.

o
r

2
,
0
0
0
2
,
5
0
0
1

y
r
.

o
r

4
,
0
0
0
5
,
0
0
0
2
3

y
r
.

o
r

8
,
0
0
0
1
0
,
0
0
0
5

y
r
.

o
r

1
6
,
0
0
0
2
0
,
0
0
0
C
o
o
l
i
n
g

W
a
t
e
r

S
y
s
t
e
m
Thermostatic
valve

Cooling water
pump

Replacement of mechanical seal

Fresh water
cooler
lic test

Cooling water
(Fresh water)
Change (depended on results of prop-
erty analysis)

Sea water cool-
ing parts
Check of anticorrosive zinc & replace-
ment (Air cooler & Lub. oil cooler)

O
t
h
e
r
Turbocharger Disassembly & cleaning

Boost air cooler
lic test

Starting air
motor
Disassemble and clean the muffler ele-
ment. (Clean with neutral detergent.)
Every 6 months
Remove the starting motor from the
engine and turn the pinion gear manu-
ally, check that it turns smoothly and it
emits no abnormal sound.
Every 6 months
replacement of o-ring, first reduction
gear bearing and special grease inside
the reduction gear.

replacement of o-ring, 1st & 2nd reduc-
tion gear bearings and special grease
inside the reduction gear.
Engine tachome-
ter
Calibration of indication

Alarm switch Actuation test

2002.5.15R
6-9
6-3. Routine Maintenance Checking & Adjusting Procedures
6-3-1. Measurement of Running Performance
Check and record the following engine performances once a day while the load is stable.
(1) Each cylinder internal max. combustion pressure (Pmax)
(2) Each cylinder outlet exhaust gas temperature
(3) Turbocharger inlet exhaust gas temperature
(4) Lub. oil temperature (at the cooler inlet)
(5) Lub. oil temperature (at the engine inlet)
(6) Cooling water temperature (at the engine inlet)
(7) Cooling water temperature (at the engine outlet)
(8) Cooling water temperature (at the air cooler inlet)
(9) Cooling water temperature (at the air cooler outlet)
(10) Cooling water temperature (at the lub. oil cooler outlet)
(11) Boost air temperature
(12) Engine inlet fuel temperature (for engine using H.F.O.)
(13) Each pressure indicated on the gauge panel
(14) Room temperature
Drawing 6-1 (1/2) Running Performance Confirming Points
Drawing 6-1 (2/2) Running Performance Confirming Points
Fuel Oil Pressure Gauge
Operating Side
Non-operating Side Engine Front End
(Maintenance Checking&Adjusting Procedures)
6-10
Compare readings with corresponding valves given in the Records of Shop Trial or the Records of Transfer
Trial, and if found to be abnormal, carry out an adjustment or servicing required.
Refer to the following items since the engine performance vary according to the room temperature,
water temperature, conditions of load, etc.
(1) The dispersion of the maximum combustion pressure (Pmax) among cylinders is normal if it is
within 0.5Mpa (5kgf/cm
2
).
Pmax may rise considerably as depended on properties of fuel oil. However, in any case, run the
engine to keep Pmax below 17.7Mpa (180kgf/cm
2
).
Reflation between the Pmax and the boost air temperature
If the room temperature rises, Pmax falls; conversely, if the room temperature drops, Pmax rises.
There is a tendency of Pmax 0.2 MPa (2kgf/cm
2
) against the room temperature change 3 .
(2) Exhaust temperature refers to the corresponding temperature recorded in the Transfer Trial.
The dispersion of the exhaust temperature among the respective cylinder outlets is normal if it is
within 40 .
Even if this temperature is found not uniform among cylinders, it is unnecessary to force revising this
non-uniformity if the fuel injection volume and Pmax are found uniform among cylinders.
If the dispersion of the exhaust temperature among individual cylinder outlet is more than 40 and
the exhaust temperature at individual cylinder outlet has dropped more than 40 of the mean
exhaust temperature at each cylinder outlet, immediately stop the engine, investigate the cause of
problem and repair the engine avoid misfiring which is often the cause of wrong influence on the tor-
sional vibration.
Even if above mentioned dispersion is more than 40 and the mean exhaust temperature at each
cylinder outlet is within the limits of 40 , would you stop and repair the engine suitably because of
unbalance for the engine combustion performance.
Relation between the room temperature and the exhaust temperature.
The exhaust temperature varies at the rate of about twice the room temperature change. Neverthe-
less, use the engine within the limit values, maintaining a good servicing of the engine, etc. and
reducing the load because fouling of turbocharger and suction/exhaust passage, exhaust pressure,
properties of fuel oil, etc. may influence this relation.
6-3-2. Measurement of Max. Combustion Pressure (Pmax)
Wear gloves when taking a measurement because the pressure indicator becomes hot.
(1) Prepare the following exclusive tools:
No.
Exclusive Tool
Description
Part No.
Pressure indicator
cock turning handle
153605 - 92360
Pressure indicator 137600 - 93751

Turning Handle
Inserting Hole
Max. Pressure Indicator Cock
Valve
Drawing 6-2. Pmax Measurement Procedures
2009.2.25R
6-11
(2) Open the valve of pressure indicator cock with use of pressure indicator cock turning handle , and
lightly race/rev up the engine for two to three times.
(For prevention of dust and foreign matter from intruding into pressure indicator)
(3) Attach the pressure indicator , and close its exhaust valve .
(4) Be sure to fully open the valve of pressure indicator cock withe use of turning handle, and close the
indicator cock when the pressure becomes the highest.
(5) After reading out the Pmax, open the exhaust valve of pressure indicator.
(6) Detach the pressure indicator when its needle shows 0 MPa (0 kgf/cm
2
).
(When the pressure indicator cock is found hard to loosen, use the turning handle.)
(1) Should the dispersion in Pmax among cylinders exceed 0.5MPa(5kgf/cm
2
), adjust it with the injec-
tion timing of within 1.
(2) Should the Pmax exceed its limiting value, adjust the injection timing upon examining the engine
performances.
6-3-3. Regulation of Fuel Injection Volume (Rack Scale)
(1) Should the dispersion in exhaust temperature among cylinders exceed 40 under the serviced
state of the fuel injection valve, adjust the rack of the corresponding fuel injection pump.
(2) Keep the range of dispersion of rack adjustment among cylinders within one scale graduation.
Drawing 6-3. Fuel Injection Volume Regulating Procedures
(1) Loosen the lock nut .
(2) Turn the adjusting screw as follows:
Clockwise: To increase the injection volume (exhaust temperature rise)
Counterclockwise: To decrease the injection volume (exhaust temperature drop)
(3) Tighten the lock nut.
Fuel Injection Pump
Rack
FUEL DECREASE FUEL INCREASE
FUEL VOL.
6-12
6-3-4. Adjustment of Fuel Injection Timing
If it is necessary to adjust the fuel injection timing as based on the data recorded during a load run, stop
the engine, and adjust the timing according to the following procedures:
1) Procedures for checking the fuel injection timing
(1) Turn the flywheel to align the marked-off line on the body of fuel injection pump with that on the
plunger guide.
(2) The scale graduation pointed out by the flywheel pointer at this time indicates the fuel injection timing.
(The flywheel scale within the range of 0 to 30from the T.D.C. is graduated in 2, and outside the
range, 5.)
2) Adjustment of the injection timing
Do not bring your fingers close to the lock nut nor oil shield plate while turning the flywheel. Other-
wise, your fingers may be caught in, resulting in an injury.
Drawing 6-4. Fuel Injection Timing Adjusting Procedures
(2) Turn the flywheel to position the adjusting bolt at the lowermost.
(4) Turn the flywheel in the direction of engine rotation so as to align the flywheel pointer with the injection
timing (indicated by the flywheel scale) of a cylinder to be adjusted.
Advance the injection timing: Pmax rises.
Delay the injection timing: Pmax drops.
Exclusive Tool Description Part No.
Single-ended wrench (M24) for adjusting bolt 138603 - 92510
Double-ended wrench 28110 - 220240
Ratchet handle for turning 147673 - 92851
Socket (M24) for turning 42111 - 001850
Fuel Injection Pump
Maked-off Line
Oil Shield Plate
2006.3.31R
6-13
2000.8.8R
(5) Turn the adjusting bolt to align the marked-off line on the pump body with that on the plunger guide.
(6) Turn the flywheel to position the adjusting bolt at the lowermost.
(7) Tighten the lock nut.
(Have the adjusting bolt fixed with use of a wrench so as not to allow the bolt to turn together when
lock nut is tightened.)
After having adjusted the injection timing, turn the flywheel in the direction of engine rotation. When
the adjusting bolt has come to its uppermost position, further push up the oil shield plate to make sure
there is allowance for the pump stroke. (Use the fuel pump priming tool.)
Drawing 6-5. Fuel Injection Pump Priming Tool
6-3-5. Checking of Fuel Injection Valve & Adjustment of Injection Pressure
Improper servicing of fuel injection valve greatly affects the fuel combustion and output. However, it is gen-
erally difficult to specify the servicing frequency which depends on such as the fuel oil used and service
load. Therefore, determine the proper servicing frequency based on such as changes of exhaust tempera-
ture and exhaust color.
In the engine using high viscosity fuel oil, the fuel injection nozzle is indirectly cooled. For servicing
and dismantling the fuel valve, refer to Fig. 36-C: Fuel injection maintenance procedure.
1) Drawing-out of a fuel injection valve
Priming lever 146673 - 92920
Lever support 146673 - 92930

Body of fuel injection valve drawing-out tool 146673 - 92340
Drawing-out bolt 146673 - 92330
Nut 26732 - 160002

Hexagonal wrench key (M8) 28150 - 080000
Operate
Tappet
6-14
Drawing 6-6. Fuel Injection Valve Drawing-out Procedures
(2) Remove the clamping bolts of fuel injection pipe joint with use of hexagonal wrench key. (Also
remove the bolts on the fuel injection pump side.)
(3) Loosen the cap nut of fuel injection pipe , and remove it with the fuel injection pipe.
(4) Remove the fuel valve tightening nut.
Handle the injection pipe with care because oil leakage takes place if the spherical surface on either
end of fuel injection pipe is flawed.
(5) Screw the drawing-out bolt into the fuel valve guard.
(6) Attach the body of drawing-out tool .
(7) Tighten the nut to draw out the fuel valve.
(8) Draw out the case nut packing. (It may be drawn out together with the fuel valve.)
2) Incorporating the valve
After cleaning, check or replacement of the fuel valve and adjustment of fuel injection pressure is finished,
incorporate the fuel valve while observing the following point:
(1) Take care not to damage the tip of nozzle sleeve when clearing the fuel valve mounting hole.
(2) Replace the case nut packing with new one.
(3) First tighten the cap nut of fuel injection pipe, and then tighten the fuel valve tightening nut.
(4) Do not make a mistake in the incorporating direction because spherical washers are used to the
injection pipe joint clamping bolts on the fuel injection pump side.
(5) Tighten the clamping bolts of fuel injection pipe joint on the cylinder head side and the fuel injec-
tion pump side alternately and gradually in two or three times.
Rocker Arm
Shaft Pedestal
Fuel Valve Tightening Nut
Fuel Valve Guard
Nozzle Sleeve
Case Nut Packing
<Prevent leakage oil in the fuel
injection valve from dropping
in the cylinder liner>
Before the fuel injection valve
slips out, remove the bolt (B)
(Refer drawing 6-7, p6-15) of
pipe coupling. Leakage oil in
the fuel injection valve can be
exhausted if it does so.
Additionally, blowing by com-
pressed air can effectively
exhaust the leakage oil.
2006.1.20R
6-15
3) Leaked oil check
During a run immediately after servicing of a fuel injection valve, check for oil leaked from the overflow
pipe.
(A) Leaked oil take-off part of the injection pipe and injection pipe joint
(B) Leaked oil take-off part from the nozzle clearance.
Drawing 6-7. Leaked Oil Take-off Parts
4) Disassembly & cleaning of a fuel injection valve
(2) Clean carbon adhered to the nozzle exterior, and then disassemble the fuel injection valve. (Removal
of carbon is facilitated by soaking the nozzle in the carbon remover or stock solution of cresol.)
(3) First remove the fuel valve guard, and then disassemble the valve sequentially in the ascending order
of numbers shown in the drawing below.
Socket for case nut 146673 - 92260
Single-ended wrench (M41) for pressure regulation 146673 - 92270
6-16
2001.2.28R
Drawing 6-8. Fuel Valve Disassembling Sequence
(4) Check & servicing of various parts
Check for sulfuric acid corrosion on the periphery of nozzle . If found noticeable corroded, replace the
nozzle with a new one.
If the nozzle valve has stuck of it does not move smoothly, replace it with a new one.
When the stepped wear "A" of valve stop spacer exceeds 0.15mm, replace it with a new one.
Replace the case nut and O-rings of body of fuel injection valve with the respectively new ones.
You are recommended to hold spare parts of nozzle, supposing that its average service life is about 2,500
hours.
(5) Reassemble a fuel injection valve in the sequence reverse to disassembly, paying attention to the fol-
lowing paints:
(1) Do not make a mistake in the incorporating direction of the spring seat , spring shoe and
spring shoe guide .
(2) Tighten the case nut to the specified torque using an exclusive socket. Excessively tightening it
may cause the nozzle to malfunction and the straight pin to be broken.
Chapter9. Table or Tightening Torques of Major Bolts
Fuel Injection Valve
Guard (Flange)
Holder
Holder
O-ring
A
O-ring
O-ring
O-ring
O-ring
Holder Set Bolt
Flange
6-17
5) Injection test & injection pressure regulation
When operating the nozzle tester, be careful not to expose any part of your body to spray from the
injection valve.
If exposed, you would be seriously wounded because the injection pressure is very high at 34MPa
(347kgr/cm
2
)
Drawing 6-9. Injection Test & Injection Pressure Regulating Procedures
Set the fuel injection valve downwards.
(2) Attach the injection valve to the nozzle tester.
(3) While slowly operating the hand lever of the tester, adjust the screwing-in of the pressure adjusting
nut to attain the specified injection pressure.
(4) Quickly operate the hand lever of the tester (at rate of two to three strokes per second), and check the
state of spray. If the hand lever of the tester is operated slowly at this time, fuel oil runs down after the
hand lever is stoked, and you might err in judgment that the nozzle is defective. Thus, pay attention to
this regard.
Replace such a clogged nozzle or nozzle which gives a streaky injection with the new one.
(5) The nozzle can be used continually if the oil tightness of the seat part maintains a pressure 2.0 MPa
(20kgf/cm
2
) lower than the specified injection pressure and allows the fuel oil to such an extent of
oozing out from the nozzle tip.
Nozzle tester 737600 - 93110
Injection pipe for nozzle tester 141616 - 93420
Single-ended wrench (M41) for pressure regulation 146673 - 92270
Socket for case nut 146673 - 92260
Double-ended wrench (M41 M46) 28110 - 410460
Injection Pipe
for Nozzle Tester
Nozzle Tester
Case Nut
2004.11.25R
6-18
(1) When replacing the nozzle, remove the case the case nut under the loosened state of the pressure
adjusting nut. If the case nut is loosened under a high state of the injection pressure, the mating
surfaces of nozzle and spacer and the straight pin may be damaged.
(2) Tighten the case nut to the specified torque with use of exclusive socket.
(6) When the injection test and adjustment of injection pressure are finished, tighten the lock nut with
an exclusive single-ended wrench. (To prevent the adjusting nut from being turned together with
the lock nut, lock it with a double-ended wrench.)
6-3-6. Adjustment of Suc./Exh. Valve Head Clearance
Adjust the suction/exhaust valve head clearance according to the following procedures because the valve
mechanism of this engine is so constructed to retain two suction (or exhaust) valves by means of the T-
shaped valve guard which will be distorted to cause an abnormal wear to the valve guard guide and/or
valve guide unless adjusted to retain two valves simultaneously:
Drawing 6-10. Valve Head Clearance Adjusting Procedures
(2) Turn the flywheel to bring the cylinder for which the clearance is to be adjusted to assume the T.D.C.
of the compression stroke.
Do not mistake the T.D.C. of overlap for the instructed T.D.C.
Feeler gauge, 0.3-mm thick (suction) 28312 - 300750
Feeler gauge, 0.4-mm thick (exhaust) 28312 - 400750
Valve Guard
C
A
B
6-19
(3) Loosen the lock nuts & , and then loosen the rocker arm adjusting screw and valve guard
adjusting screw .
(4) Press down the center of the valve guard from above (so that the clearance becomes zero under
this condition). Gradually tighten the valve guard adjusting screw so that the clearance
becomes zero. After the adjustment, lock the adjusting screw not to turn, and securely tighten the
lock nut .
(5) Put a feeler gauge into a clearance between the rocker arm adjusting screw and the valve guard,
and gradually tighten the rocker arm adjusting screw until the clearance becomes narrow enough
to permit the feeler gauge to be smoothly drawn out. Then, lock the adjusting screw , and tighten
the lock nut .
(6) After having securely tightened the lock nut , check that the feeler gauge can be smoothly drawn
out.
The valve head clearance of a suction valve and that of an exhaust valve are different. Be careful not
to mistake the clearance of one valve for that of the other.
Valve head clearance: Chapter 3. Table of Engine Standard Adjustments
6-3-7. Adjustment of Lub. Oil Pressure
The lubricating oil pressure regulating valve has been integrated in the lubricating oil pump.
Should the lubricating oil pressure go out of the specified value, adjust it according to the following proce-
dures:
(1) Before adjusting the lub. oil pressure, first clean the lubricating oil strainers.
(2) Run the engine, and then adjust the lubricating oil pressure to the specified value only after the
lubricating oil temperature is stabilized.
Drawing 6-11. Lub. Oil Pressure Adjusting Procedure
(2) Adjust the screwing-in of the adjusting
bolt to regulate the pressure.
Clockwise ... The pressure rises.
Counterclockwise ...
The pressure drops.
(3) Securely tighten the lock nut.
Lub Oil Pump
6-20
6-3-8. Adjustment of Lub. Oil Temperature
An automatic thermostatic valve has been equipped to the lubricating oil cooler to rise the lubricating oil
temperature in a short time after the engine is started and to maintain the temperature in the proper range
during a run. The lubricating oil temperature varies with a change of the cooling water temperature in each
season and sea aria, a fluctuation in the cooling water flow rate, fouling of the lubricating oil cooler, etc.
The automatic thermostatic valve has been set so that the lubricating oil temperature at the engine inlet
becomes 50 to 65 . However, if the lubricating oil temperature exceeds this range, adjust and check it
according to the following procedures:
1) Adjustment of lubricating oil temperature
Drawing 6-12. Lub. Oil Temperature Adjusting Procedures
(1) Remove the cap nut , and loosen the lock the lock nut .
(2) Check the projecting dimension of the adjusting bolt .
(3) Screw the adjusting bolt in the direction of an arrow shown on the nameplate, and make sure the tem-
perature drops. (The bolt screwing-in depth must be 17mm or less.)
Should the temperature do not drop even after the above adjustment, fouling of the lubricating oil
cooler, sticking of a piston of malfunction of the element, etc. may be suspected. Investigate the
cause, and restore the engine to the former proper condition.
Element
Piston
Nameplate
Cover
6-21
2) Check of automatic thermostatic valve
Stop the engine discharge the lubricating oil from the lubricating oil cooler, and then check the automatic
thermostatic valve according to the following procedures:
(1) Loosen the bolt shown in Drawing 6 -12, and then detach the cover.
(2) Check if the piston moves smoothly. (If the piston is catching or stuck, restore it to the proper condi-
tion.)
(3) Take out the piston (incorporating the element withe a circlip)
(4) Soak the element in cold water and warm water for 3 to 5 minutes, respectively, and measure the lift
of element spindle.
Drawing 6-13. Element Checking Procedures
Lift of the element spindle (normal part)
(5) If the lift of element spindle does not satisfy the values shown in the above table, replace the element
with the new one.
(6) Adjust the projecting dimension of the adjusting bolt to 36mm, and then attach the cover.
Checking Water Temperature Lift
Cold water of 30 or less 5 0.1mm
Warm water of 65 or more Greater than 23mm
Element
Piston
Spring
Circlip
Element Spindle
6-22
6-3-9. Adjustment of Fuel Oil Pressure
The fuel oil pressure regulating valve is equipped to the end of fuel oil return pipe together with a damper
which absorbs the pulsating pressure inside the return pipe.
Drawing 6-14. Pressure Regulating Valve Equipped Point
(1) Before adjusting the fuel oil pressure, first clean the fuel oil filters.
(2) Adjust the fuel oil pressure, taking the tank head pressure into consideration.
Drawing 6-15. Fuel Oil Pressure Adjusting Procedures
(1) Turn the pressure adjust screw as follows:
Clockwise ... The pressure rise.
Counterclockwise ... The pressure drops.
Fuel Oil Pressure Gauge
Pressure Regulating Valve
Damper
Fuel Oil Inlet
Fuel Oil Outlet
Adjusting Screw
6-23
6-3-10. Checking of Cyl. Jacket Cooling Water Thermostatic Valves
An automatic thermostatic valve has been equipped to cylinder jacket to rise the cylinder jacket cooling
water temperature in a short time after the engine is started and to maintain the temperature within the
proper range during a run.
This automatic valve has been set so that the cooling water at the engine outlet becomes 85 when the
cold fresh water temperature is 38 .
When the engine is operated at low load or when heat discharge, the cooing water temperature naturally
drops, but there is no problem of sulfuric corrosion as far as the cooling water temperature at engine outlet
is maintained over 75 .
Overhaul, and check the thermostatic valve according to the following procedures.
Drawing 6-16. Thermostatic Valve Removing Procedures
1) Removal of thermostatic valve elements
(1) Close each valve at the inlet and outlet of the cooling water system, and then discharge the cooling
water from inside the cylinder jacket.
(2) Remove the air bleeder.
(3) Detach the side cover.
(4) Remove the thermostatic valve case, and take out the elements.
Be careful not to drop the thermostatic valve elements.
Air Bleeder
Throttle Plate (Orifice)
Thermostatic Valve Case
Thermostatic Valve Element
Side Cover
Throttle Plate (Orifice)
Jacket Cooling Water Pump
2006.12.15R
6-24
2) Check of thermostatic valve elements
The thermostatic valve is equipped with two elements of different valve opening temperatures.
Check the elements according to the following procedures:
(1) Check for crack of the valve, broken spring and foreign matters caught on the valve seat face.
(2) Soak the elements in cold water and hot water for 2 to 3 minutes, respectively, and measure the valve
lift .
Drawing 6-17. Element Checking Procedures
Valve lift of the element (normal part)
(3) If the valve lift does not satisfy the values shown in the above table, replace the elements with new
one.
3) Incorporation thermostatic valve elements
Incorporation thermostatic valve element in the sequence reverse to removal.
(1) Do not make a mistake in the element incorporating direction.
(2) Do not forget to incorporate throttle plates at thermostatic valve case inlet and outlet sides.
6-3-11. Cleaning of Lub. Oil Bypass strainer
The lubricating oil system is equipped with a centrifugal bypass strainer in addition to a notch-wire oil
strainer. During a run, keep open a cock at outlet of lub. oil pump to allow the lubricating oil to flow through
the strainer regularly. When any problem has occurred to the bypass strainer, close the cock to stop the oil
flow.
Stop the engine before cleaning the bypass strainer.
If you disassemble the bypass strainer during a run, oil mist may be blown off, causing you to get a
burt.
Checking Water Temperature Lift
Cold water of 30 or less 45 1mm
Hot water of 95 to 100 Greater than 55 1mm
Valve Valve Opening Temp. Stamp
6-25
1999.7.2R
GF-2type Bypass Strainer
1) Disassembly & cleaning
Disassemble and clean the lub. oil bypass strainer according to the following procedures:
Drawing 6-18. GF-2type Bypass Strainer Disassembling Procedures
(1) Loosen the tightening nut of the body cover , and then remove the cover .
(2) Remove the rotor assembly (spindle, rotor cover and rotor body ).
(3) Lock the nozzle section of rotor assembly.
When locking the nozzle section, take care not to flaw the nozzle hole and the spindle bearing.
(4) Loosen the rotor cover tightening nut , and then detach the rotor cover .
(5) Completely remove the sludge adherent to the rotor body and inside of rotor cover , and then
wash them.
Completely remove the sludge. Otherwise, the residual sludge may cause an unbalance in rotation,
resulting in a damage to the bearing.
(6) Check for flaws of the bearings of body and body cover.
2) Reassembly
Reassemble the lub. oil bypass strainer in the sequence reverse to disassembly, paying attention to the
following points.
(1) Check for clogging of the nozzle and damage of the nozzle hole before incorporating the rotor
cover.
(2) Incorporate the body cover after incorporating the rotor assembly into the body and making sure it
rotates smoothly.
Bearing
Spindle
Body
Bearing
Lub. Oil Inlet
Lub. Oil Outlet
Nozzle
6-26
ROC-5type Bypass Strainer
Disassemble and clean the lub. oil bypass strainer according to the following procedures:
(1) Loosen the bell knob 1/4 turns and remove the bell clamp, then remove the bell housing.
(2) Raise up the turbine assembly to allow the lub. oil to drain from inside, then remove the turbine
assembly.
Take care not to bend the base shaft.
(3) Loosen the can nut, then turn over the turbine assembly withe the can nut loosely attached.
If the can nut is too tight to loosen with your hands, insert a bar into the hole of can nut and turn the
bar.
Take care not to scratch the end surface of bush.
(4) Press down the turbine can, then remove the nut, turbine can and baffle screen.
Drawing 6-19. ROC-5type Bypass Strainer Disassembly Procedures
2) Checking and servicing
Sludge whose thickness is 15mm or more may cause abnormal vibration. According to the operation con-
ditions, specify the proper servicing interval.
(1) Insert such a narrow and thin tool as a spatula between the inside wall of turbine can and paper insert
to remove sludge and paper insert.
(2) Clean the turbine can, baffle screen and turbine rotor.
Completely remove the sludge. Otherwise, abnormal vibration may be caused.
(3) Check for clogging of nozzle.
(4) Replace the O-ring, gasket and paper insert with new ones, respectively.
3) Reassembly
Reassembly the lub. oil bypass strainer in the sequence reverse to disassembly, paying attention to the fol-
lowing points.
Tighten the can nut and bell clamp only with your hands and fingers.
Attach the turbine assembly to the bell shaft, then make sure that it can be smoothly turned.
Tighten the bell clamp, then tighten the can nut 1/4 turns.
Bell Knob
Bell Housing
Bell Clamp
O-ring
O-ring
Base Shaft
Base
Can nut
Can nut
Turbine Can
Turbine Can
Turbine Rotor
Paper Insert
Baffle Screen Assy.
Bush
Bush
Bush
Bush
Nozzle
Cut-off Valve
[on Opposite Side of Lub. Oil Inlet]
Disassembly of Turbine Assy.
Turbine Assy.
1999.7.2R
6-27
FM200 type Bypass Filter
This FM200 centrifugal bypass filter should be cleaned at regular intervals ensuring that the thickness of
the dirt deposit inside the rotor does not exceed approximately 35 mm.
The filter assembly is fitted with a cut off valve, which is located in the filter body. This valve is designed to
protect the engine by stopping the supply of lube oil to the filter at start-up and during periods when the oil
pressure is below the valve rating.
Disassemble and clean the lube oil bypass filter according to the following procedures:
Drawing 6-18-b FM200 type Bypass Filter
11
1O
9
8 7 6
18
14 16
16
17
18
19
2O
21
22
4
2
8
6
1
12
1
2
8
4
6
6
7
8
9
1O
11
12
18
14
16
16
17
18
19
2O
21
22
FLANGE GASKET
CUT OFF VALVE KIT
O-RING (FILTER BODY)
NOZZLE
ROTOR BODY
O-RING (ROTOR ASSEMBLY)
CIRCLIP
PAPER INSERT
ROTOR COVER
STAND TUBE
BEARING TUBE
NAME NAME
ROTOR ASSEMBLY
ROTOR COVER NUT
STIFFNENER PLATE
COVER
O-RING
COVER NUT
COVER ASSEMBLY
COVER CLAMP
SPINDLE
BODY
BODY ASSEMBLY
LUB.OIL
INLET
LUB. OIL
OUTLET
pin
roter cver
slot
rotor boar1n_
2006.1.20R
6-28
(1) Ensure the engine stopped, and the filter has come to a complete stop before proceeding.
(2) Remove the band clamp ,unscrew the cover nut and remove the centrifuge cover assembly .
(3) Allow the oil to drain out of the rotor assembly . Withdraw the rotor assembly vertically upwards
from the spindle.
At this time, it is noted not to damage an upper and lower rotor bearing.
(4) Secure the rotor assembly on the rotor disassembly tool. Unscrew the rotor cover nut and sepa-
rate the rotor cover from the rotor body .
(5) Remove the stand-tube .
(6) Remove sludge deposits from the inside of the rotor cover using a spatula, and remove the paper
insert from the rotor cover. Clean the rotor components using a suitable cleaning fluid.
2) Reassembly
(1) Ensure that all rotor components (including the two nozzles located in the rotor body) are thoroughly
cleaned and free from debris before reassembly.
Completely remove the sludge. Otherwise, the residual may cause an unbalance in rotation, resulting
in damage to the bearing.
(2) Fit a new paper insert into the rotor cover, and attach the whole rotor assembly component. And then
tighten with the rotor cover nut .
Examine the centrifuge body O ring for damage and renew if necessary.
Inspect rotor bearings for wear and replace bearing tube if necessary.
Reassemble the rotor assembly ensuring that the rotor cover slot and rotor body pin are aligned.
This prevents the unbalance during operation.
(3) Replace the rotor assembly on the spindle.
Inspect spindle for wear and replace filter body assembly if necessary.
After replacing the rotor assembly, check the rotor spins freely.
(4) Replace the filter cover assembly and fasten the centrifuge cover nut hand tight. (Tightening
torque =5 7 Nm)
Examine the filter body O ring for damage and renew if necessary.
(5) Replace the cover clamp and tighten hand tight. (Tightening torque =5 7 Nm)
The band clamp must be securely fitted during operation of the centrifuge.
(6) With the centrifuge running, check all joints for leaks.
2006.1.20R
6-29
1999.7.2R
6-3-12. Cleaning of Lub. Oil Strainer
Engine Main Lubricating Oil Strainer
The lubricating oil strainer is of the manual back-washing, duplex changeover type, and its element are of
the notch-wire type. In a normal run, the lubricating oil passes through both sides (both elements) of the
strainer.
Besides, a differential pressure indicator which detects the oil pressure at the inlet and outlet of the strainer
has been fitted to the lubricating oil cooler so as to detect clogging of the strainer.
When the difference between the oil pressures at the inlet and outlet of the strainer reaches 0.09 MPa
(1kgf/cm
2
), the differential pressure alarm is issued.
Be careful not to get burnt by touching this strainer because it assumes a high temperature during a
run.
Should the differential pressure not drop even if back-washing is done, overhaul and clean the
strainer.
Should the strainer be fouled noticeably, a lub. oil pressure drop alarm may be issued when one side
of this strainer is used. Therefore, check the oil pressure while cleaning the strainer.
1) Back washing (blow-off)
Wash both sides of this strainer, one at a time, according to the following procedures:
(1) Align the red mark of the changeover cock with the LEFT (or RIGHT) CHANGE position on the
nameplate.
(2) Loosen the drain plug two to three turns.
(3) Carry out the changeover cock with the LEFT (or RIGHT) BLOW-OFF position for 1 to 2 seconds.
(4) Return the changeover cock with the CHANGE position.
(5) Repeat the above operation steps (3) & (4) three or four times.
(6) Tighten the drain plug.
(7) Return the changeover cock to the NORMAL RUN position.
Drawing 6-20. Lub. Oil Strainer Cleaning Procedures
Changeover Cock Nameplate
LEFT CHANGE
LEFT BLOW-OFF
NORMAL RUN
Case
O-ring
22.5
6-30
1999.7.2R
When disassembling this strainer during a run, do so one side of the strainer at a time according to the fol-
lowing procedures:
(1) Align the red mark of the changeover cock with the LEFT (or RIGHT) CHANGE position.
(2) Loosen the drain plug .
(3) Loosen the air vent plug .
(4) Discharge the lubricating oil in the case, loosen the nut , and then detach the blow-off pipe .
(5) Loosen the center bolt , and remove the case and element.
(6) Clean the removed.
6-3-14. Cleaning of Strainer/Filter Element
3) Incorporation
Incorporation a strainer element in the sequence reverse to disassembly, paying attention to the following
points.
Do not make a mistake in the element incorporating direction.
Take care not to permit the O-ring bit in the case.
When setting the changeover cock in the NORMAL RUN position, shift it slowly. If shifted rapidly, the
oil pressure may temporarily drop before the case is filled with the lubricating oil, causing the lubricat-
ing oil pressure drop alarm to be issued.
Turbocharger Lubricating Oil Strainer
The lubricating oil strainer is of the duplex changeover type and its elements are of the paper type. In a
normal run, the lubricating oil passes through both sides (both elements) of strainer.
Besides, a pressure switch is provided on the outlet side of strainer to detect clogging of the strainer.
When the lub. oil pressure at the outlet of strainer has dropped to 0.3 MPa (3kgf/cm
2
), replace the ele-
ments of the strainer.
When the lub. oil pressure at the outlet of strainer has dropped to 0.25 MPa (2.5kgf/cm
2
), the pres-
sure drop alarm will be issued.
Simultaneously, the relief valve of strainer will open to allow sludge and contaminant in the strainer
to flow to the turbocharger, thereby damaging the bearing. Take care not to let the lub. oil pressure
to drop excessively.
If the strainer is fouled noticeably, the lub. oil pressure drop alarm may be issued when one side of
this strainer is used. Therefore, keep checking the pressure carefully while operating one side of this
strainer.
Be careful not to get burnt by touching this strainer because it assumes a high temperature during a
run.
6-31
1999.7.2R
If you disassemble the strainer during a run, disassemble and clean on element then the other sequen-
tially.
(1) Align the red mark of the changeover cock with the LEFT (or RIGHT) CHANGE position.
(2) Loosen the air vent plug.
(3) Remove the drain plug, and discharge the lub. oil from the case.
(4) Loosen the center bolt, and remove the case and element.
(5) Replace the element.
Drawing 6-21.
2) Incorporation
Incorporate a strainer element in the sequence reverse to disassembly, paying the attention to the follow-
ing points.
Do not make a mistake in the element incorporating direction.
Take care not permit the O-ring bite in the case.
When setting the changeover cock in the NORMAL RUN position, shift it slowly. If shifted rapidly, the
oil pressure may temporarily drop before the case is filled with the lubricating oil, causing the lubricat-
ing oil pressure drop alarm to be issue.
6-3-13. Cleaning of Fuel Oil Filter
The fuel oil filter equipped is of the heat-insulating, manual back-washing, duplex changeover type, and its
elements are of the notch-wire type. In a run, the fuel oil passes through both sides (both elements) of this
filter.
Be careful not to get burnt by touching this filter because it assumes a high temperature during a run
on H.F.O.
Pressure Gauge
Pressure Switch
Relief Valve
Air Vent Plug
Changeover Cock
O-ring
Case
Element
Drain Plug
Center Bolt
LEFT CHANGE
NORMAL RUN
RIGHT CHANGE
6-32
2003.4.17R
Should the filter be fouled noticeably, the revolution of the engine may decrease as the fuel oil pres-
sure drops when one side of this filter is used. Therefore, check the fuel oil pressure while cleaning
the filter.
A positioning notch is provided to the changeover handle. In a blow-off or disassembly, tilt the handle
to align the notch with the knock pin.
1) Back-washing (blow-off)
Wash both sides of this filter, one at a time, according to the following procedures:
(1) Open the drain cock .
(2) Hold the changeover handle in the LEFT (or RIGHT) BLOW-OFF position for 1 to 2 seconds, and then
return it to the BOTH SIDES IN USE position.
(3) Repeat the above step (2) three or four times.
(4) Close the drain cock.
Drawing 6-22. Fuel Oil Filter Cleaning Procedures Drawing 6-23.
When disassembly this filter during a run, do so one side of the filter at a time according to the following
procedures:
(1) Tilt the changeover handle to the LEFT (or RIGHT) DISASSEMBLY position.
(2) Open the air vent cock .
(3) Open the drain cock to discharge the fuel oil.
(4) Remove the circular nut .
(5) Remove the element , and clean it.
(6) Clean the inside of the filter body.
LEFT
BLOW - OFF
LEFT
DISASSEMBLY
80
50
BOTH SIDES IN USE
H.F.O. Filter
LEFT
BLOW - OFF
LEFT
DISASSEMBLY
90
60
BOTH SIDES IN USE
M.D.O. Filter
6-33
3) Incorporation
Incorporation a filter element in the sequence reverse to disassembly, paying attention to the following
point.
(1) When setting the handle in the BOTH SIDES IN USE position, shift it slowly. If shifted rapidly to the
BOTH SIDES IN USE position, the oil pressure may drop before the filter is filled with the fuel oil.
(2) Open the air vent cock to bleed air.
Clean a notch-wire type element of lubricating oil strainer or fuel oil filter according to the following proce-
dures:
Drawing 6-24. Notch-wire Type Element Cleaning Procedures
(1) Soak the element in the light oil or cleaning fluid to remove the sludge adherent on the surface with a
wire brush.
(2) Prepare a nozzle as shown in the above drawing, and spray the compressed air of 0.3 to 0.5 MPa (3
to 5 kgf/cm
2
) from the inside of the element.
(3) Lighting the element form its inside, make sure the dirt and foreign matters have been removed.
(4) Check for flaws, wire breakage, corrosion, etc. on the surface of notch wire.
6-3-15. Washing of Turbocharger Blower
1) Washing of Turbocharger Blower
When the blower of turbocharger is fouled, the exhaust temperature may rise, shortening the service life of
fuel injection valves and exhaust valves.
Also, the effect of late washing is lower than that of timely washing. Therefore, record the boost air pres-
sure before and after such a washing, and referring to the recorded data, periodically wash the blower.
(1) Wash the blower during a run of about 75% or more load. After washing it, continue a load run for at
lest one hour.
(2) Should the boost air pressure not restored even after washing the blower, overhaul and clean it.
(3) Fresh water alone does not have the effect of cleaning the blower. For washing the blower, use the
cleaning fluid (P/#137616-18400).
Cock
Smash to about 1mm
8/6 Pipe
6-34
Drawing 6-25. Turbocharger Blower Washing Procedures
(1) Open the drain cock on the outlet side of boost air cooler.
(2) Suck one washings usage of the cleaning fluid into a hand pump.
(3) Connect the land pump with the water filler plug, and pour in the cleaning fluid in 4 to 10 seconds.
(4) Repeat the above steps (2) & (3) three of four times.
(5) Pour fresh water of the same quantity as the cleaning fluid into the washer, and carry out washing with
fresh water in the same way above procedures.
(6) After the washing, attach the cap to the water filler plug, and close the drain cock.
(7) If the boost air pressure is not restored, wait next 10 minutes, and then repeat the above washing.
6-3-16. Maintenance of Pressure Gauge
Glycerin aqueous solution is sealed in a pressure gauge equipped on the gauge panel to prevent wear of
the gear and link mechanism inside the gauge.
Handle a pressure gauge, observing the following items:
(1) When removing the gauge panel or a pressure gauge for its servicing, have the rubber cap of a pres-
sure gauge faced upward.
(If faced sidelong, the sealing liquid will leak through the ventilating hole in the rubber cap.)
(2) Always maintain the sealing liquid at the specified level.
One washings usage
Type RH133 : 0.15 ltr.
Type RH143 : 0.2 ltr.
Hand Pump Connecting Hose
Fillter Plug
Cap
RH133 Type RH143 Type
1998.10.20R
6-35
Drawing 6-26. Level of Pressure Gauge Sealing Liquid
(3) Should the sealing liquid become contaminated or its level drop, detach the rubber cap, and change
the sealing liquid or replenish the pressure gauge with its sealing liquid.
(Sealing liquid (P/#42111-002800) is optionally available.
(4) When a pressure gauge is replaced with the new one, use it after cutting off the navel of the rubber
cap to open a ventilating hole to the gauge.
(If the gauge is not provided with an opened ventilating hole, the indication becomes be out of order.)
Adjustment of Pressure Take-off Main Valve
Check and adjust the operating of a needle valve provided at the piping part of a pressure gauge or
pressure transmitter in order to prevent the damage or malfunction of the pressure gauge and pres-
sure transmitter that are subject to pulsation.
Fuel pressure main valve: Open 1/4 turn from the completely closed position.
Other pressure main valve: Open one turn from the completely closed position.
Adjustment of Remote Indicating Pressure
In the case of remote indication of a pressure, a pressure transmitter has been equipped. If the indication
on the remote side has to be adjusted, proceed to the adjustment according to the following procedure:
[ Adjusting Procedure ]
Detach the top cover from a
pressure transmitter.
Lightly press a small screw-
driver (of which head is 2mm
in diameter)
against the ZERO or SPAN
adjust screw, and turn the
screw as the need arises.
As the screw is turned clock-
wise, the indicated value
varies in the direction of an
arrow shown in the following
graphs.
Rubber Cap
Maximum liquid level A = 18mm
Higher liquid level B = 2526mm
014473-01E
014474-01E
SPAN
ZLRO
k_f/om
2
4
20
mA
O' k_f/om
2
4
20
mA
2mm
adjustment
Pressure Pressure
adjustment
Top Cover
Pressure Transmitter
Screwdriver
Adjustment Screw
Test Valve
Connector
Current Current
1997.9.1R
Drawing 6-27.
6-36
6-3-17. Measurement of Crankshaft Deflection
The crankshaft deflection means the gap between open and close of the crank arms, it is useful to check
the installing alignment and judge the influence on main metal damages.
If the crankshaft deflection enlarges excessively, the crankshaft may be broken, resulting in an accident.
Consequently, periodically measure the crankshaft deflection.
(1) Measure the crankshaft defection under the cold state of the engine.
(2) When you have removed of further tightened the engine installation (anchor) bolts, common bed
clamping bolts or driven machine (such as generator) clamping bolts, are disassembled or retight-
ened, measure the crankshaft deflection.
(3) Move the contactor of deflection gauge, and make sure the needle of dial gauge returns to the orig-
inal position.
1) Deflection measuring procedures
(2) Open the pressure indicator cocks of all cylinders.
(3) Turn the flywheel to bring it to the position EB of 30 degrees after B.D.C. (Bottom Dead Center)
(4) Fit the deflection gauge, and set the needle of dial gauge in the zero indication.
(5) Slowly turn the flywheel in the rotational direction of the engine, and take and record readings of the
dial gauge at the crank pin position E, T, P and PB.
Drawing 6-28. Position for Fitting the Deflection Gauge Drawing 6-29. Deflection Measuring Positions
Deflection gauge 42111 - 000040
Deflection gauge mirror 42111 - 001420
Ratchet handle for turning 147673 - 92851
Socket (M24) for turning 42111 - 001850
029059-00E
D
D/2 L
Deflection Gauge
P
PB
B
EB
E
T
30 30
Crank Pin Position
Deflection Gauge Position
(When the Crank Pin is at EB)
EB : 30 after B.D.C. (measuring reference)
(exhaust manifold side)
E : 90 before T.D.C. (exhaust manifold side)
T : Top Dead Center (T.D.C.)
P : 90 after T.D.C. (fuel injection pump side)
PB : 30 before B.D.C. (fuel injection pump side)
017779-00E
D = Crank journal diameter of 180mm
L = Crank arms width of 98mm
Calculation for deflection;
Vertical deflection = T-EB
and T-PB as well
Horizontal deflection = P-E
2009.3.12R
6-37
2) Criteria on results of the deflection measurement
Deflection readings are recorded of dial gauge at each crank pin position with the reference to the position
EB or PB.
Vertical deflection is calculated by the difference in readings of the position between T and EB, T and PB.
Horizontal deflection is calculated by the difference in readings of the position between P and E.
The relation between deflection readings of dial gauge at each crank pin position and the figure with open
and close of crank arms are defined seeing on Drawing 6-30.
Drawing 6-30.
(1) Should the deflection increase every time it is periodically measured, this is caused by the wear of the
crankshaft and/or main bearings. If the deflection of only a certain cylinder increases suddenly, it is
suspectable that the corresponding main bearing metal is abnormally worn. In these cases, check for
the pertinent parts.
(2) Since the deflection value measured under the hot state of the engine varies as depending on the
temperature existing at the measurement, it cannot be relied on as the reference. However, accord-
ing to out test results, that deflection is roughly 2/10,000 to 3/10,000 stroke (lower shrink).
3) Allowable value of the deflection
Should the crankshaft deflection exceed the allowable value, correct the deflection by redistributing the
installation shims and shaft centers of the engine and driven machine (or outer bearings).
(1) In case of the direct coupling systems A , B , & D , the normal deflection for the No.1 cylinder is
lower shrink.
(2) In case of the direct coupling systems C , adjust the deflection for the No.1 cylinder to lower spread
because the temperature rise of engine bearings becomes larger than that of generator bearings
during a run and thus the shaft center of crankshaft becomes comparatively higher.
Table: Allowable value of the deflection
[Unit:1/100mm] Note: "S" stands for stroke
Reading of Dial Gauge

Crankshaft
(lower spread) (lower shrink)
Coupling System Driven Machine
Installa-
tion Sys-
tem
No.1 Cyl. No.2 6 Cyl.
(T-PB, T-EB) (P-E)
(T-PB, T-EB)
(P-E)
A (Direct coupling)
Generator, single-
side bearing
Direct
(stationary)
-5.6 +2.8
-2S 1S
10,000
2.8
1S
10,000
2.8
1S
10,000
B (Bell housing
coupling)
Generator, single-
side bearing
Vibration
insulation
-7.5 +2.8
-2.7S 1S
10,000
C (Direct coupling)
Generator, both-
side bearing
Direct
(stationary
2.8
1S
10,000
D (Air clutch &
flexible cou-
pling)
Pump & compres-
sor
Direct
(stationary)
-5.6 +2.8
-2S 1S
10,000

2009.3.12R
6-38
Drawing 6-31. Driven Machine Direct Coupling Sistem.
Rubber Vibration Insulator
Air Clutch & Flexible
Coupling
Support
6-39
6-3-18. Adjustment of Fuel Injection Pump Pinion Lubricating Volume (for Engine Using
H.F.O.)
The pinion sleeve of fuel injection pump of an engine using the heavy fuel (equivalent to 3,500-sec. or
7,000-sec. fuel oil) has been lubricated by lub. oil. Adjust the lubricating volume according to the following
procedures:
(1) First run the engine, and then adjust the lubricating volume when the lubricating oil temperature
becomes 55 to 65 .
(2) Adjust the lubricating volume so that the lubrication becomes 1 dropful per 10 to 12 seconds.
Drawing 6-32. Lubricating Volume Adjusting Procedures
(1) Remove the cap nut from the lub. oil flow rate regulating valve, and loosen the lock nut .
(2) Fully screw in the lub. oil flow rate adjust screw .
(3) Remove the plug on the fuel injection pump side to check the lubricating volume.
(4) Gradually loosen (turn counterclockwise) the adjust screw until the lubricating volume becomes as
specified.
(5) When the lubricating volume has become as specified, securely tighten the lock nut , cap nut and
plug .
6-3-19. Maintenance of Fuel Oil Seal Pot (for Engine Using H.F.O.)
Maintenance servicing of mentioned in Section 4-1-2. (Page4-6)
Oil Flow Rate
Regulating Valve
Lubricating Point
2002.5.15R
6-40
6-3-20. Check & Replacement of Anticorrosive Zinc
In the case of the fresh & sea water 2-line cooling specification, anticorrosive zincs have been fitted to the
boost air cooler, lub. oil cooler. Check them according to the following procedures:
In the case where such anticorrosive zinc is found consumed more than 70% of the state retained by the
new article, replace it with the new one.
In the case of continuous use of such anticorrosive zinc, get rid of the oxide layer from the surface of the
zinc to expose the metallic texture.
The anticorrosive zinc for boost air cooler upper part is of the plug type. Detach the inspection window
cover from the boost air duct, and remove the plug, using a hexagonal wrench key (having the width
across flats of 17mm).
After checking and replacing an anticorrosive zinc and before fitting the inspection window cover,
check that there is no water leakage.
Drawing 6-33. Anticorrosive Zincs Equipped points
Fitting Area (Qty)
Boost air cooler
Cooling water inlet/outlet cover (2)
Water return cover (2) plug type
Lub. oil cooler
Inlet side cover (1)
Outlet side cover (1)
L
L
D
D
B B
A A
A
A
Plug
Packing
Packing
Flange
Nut
Anticrrosive
Zinc
Anticrrosive
Zinc
Anticorrosive Zinc Fitting Prosedures Boost air cooler
Lub. Oil cooler
Inspection wind cover
Boost air cooler
A-Flange Type B-Plug Type
Flange type
Dimensions of Anticorrosive Zincs (in the New-article State)
Plug type
D (mm)
L (mm)
40
40
25
95
1999.6.25R
7.MAINTENANCE SERVICING
7-1
(Volume:60pages)
7. MAINTENANCE SERVICING
7-0. Precautions in Maintenance Servicing
1) Precautions on Safety
To work safely, read the items regarding safety in the following pages:
Chapter 0. For Safe Use of Your Engine .... (p.0-2)
Chapter 0, 3. Precautions on Safety (pp.0-4 to 0-13)
(1) If the engine runs during disassembly or check, you may be caught in it, resulting in a serious acci-
dent.
Prior to servicing, return the start/stop lever to the STOP position and surely close the valves of the
starting air system to make sure the engine does not turn. Only then, proceed to disassembly or
checking work. (Be sure to changeover the control position selector switch to the ENGINE posi-
tion.)
(2) Before turning the flywheel with the turning device, make sure you do not make a contact withe any
rotating part and that rotation of the engine will not endanger you, your coworkers or other persons
around the engine. Also be sure to give a sign when turning the flywheel.
For usage of the turning device, refer to the following:
Chapter 7-0. 4) Handling Procedures for Turning Device (p. 7-4)
Prevent the self-rotation of crankshaft with the lock bar of the turning device before disassembling
of checking any moving part.
Other than turning the flywheel, return the turning device to the GEAR OUT position.
(3) Be sure to turn off the power switch before handling an electric part. Otherwise, you may receive an
electric shock or fire may be caused.
(4) During welding and grinding, sparks may be spread, resulting in fire. Therefore, do not store such
combustible materials as the fuel oil, lubricating oil and waste cloth at the working site.
In advance of maintenance and check of the engine, thoroughly read this Operation Manual to
understand the structure of the pertinent part and the nature of work to be performed and to examine
sufficiently the work procedures. If you begin the work without examining the work sufficiently, not
only the labors will be wasted but also accidents or damages of the engine due to misassembly will
be caused.
If any part is found to be damaged of not durable for further use (reaching its usage limit) as a result
of check, be sure to replace it. Besides, considering the schedule for next check, replace any part
estimated not to be durable until the next check.
If it is difficult to take any countermeasure of action on site, or if the necessary spare part is not avail-
able, consult us or your nearest sales or service agent (shown in the service network list "YANMAR
Worldwide Service" appended to this manual).
7-2
(Precautions in Maintenance)
(5) When handling a liquid, strictly observe the following precautions:
Fuel oil and lubricating oil: Flammables . . . . . . . .The lighting of fires is strictly prohibited.
Fresh-water rust inhibitor
and fresh-water antifreezing fluid: Toxic . . . . . . . .Do not drink any of them.
Battery fluid When handling the battery fluid, wear rubber

gloves and a mask, if possible, and do not allow
it to make direct contact with your skin.
If it is put o your skin, flush it.
Before discharging it, treat it according to the
instruction manual of the additive manufacturer.
Mercury (thermometer): Poisonous . . . . . . . . . . .Do not drink it. If it is put on your skin, flush it.
(6) According to the condition of working, wear protectors such as gloves, a helmet, safety shoes and
safety goggles.
During a run and immediately after the engine has stopped, the whole engine is heated. Before
working, wear gloves so as not to get burnt.
On the floor of engine room, oil is adherent and slippery. Especially when working at a height
such as on the footboard, sufficiently watch your step not to fall from there.
(7) If you disassemble a strainer/filter of piping joint immediately after the engine has stopped, hot oil or
water may be spout out due to the residual pressure.
Before disassembling a strainer/filter or removing a piping joint, close all valves for external con-
nection to the CLOSE position, and gradually loosen the air vent plug to release the internal pres-
sure. Then wrap the part with cloth or the like to disassemble or remove it.
(8) Note that spring may spring out when disassembling a valve or device which uses one or more
springs.
(9) Do not raise heavy thing forcedly by your hands. Using a chain block, lift it. Also, keep off under the
lifted heavy thing.
For the weight of major part, refer to the following:
Chapter 8, 8-2. Principal Part Mass for Disassembly & Servicing
(10) Use the proper tools. Use an exclusive tool upon understanding its function.
Carefully check for any damages to rubber hose and joints of hydraulic jacks. The high-pressure
oil may spout out from a damaged portion during operation, causing you to get an injury.
For how to use the hydraulic jack, refer to the following:
Chapter 7-0, 5) Handling Procedures for Hydraulic Jack (p. 7-5)
7-3
(Precautions in Dismantling)
2) Precautions in Dismantling, Servicing & Reassembly
Be sure to observe the following precautions because the performance of the product may be deteriorated
or the machine may break down if you neglect any of the following precautions.
(1) Prepare the necessary tools and spare parts in advance.
As for the exclusive tools, use the specified tools; as for the spare parts, use our genuine parts or
the parts specified by us.
(2) If any part is found to be damaged or not durable for further use as a result of check, be sure to
replace it. Besides, considering the schedule for next check, replace any part estimated not to be
durable until the next check.
Chapter 10. Clearances & Wear Limits of Major Parts
(3) During disassembly, cover any exposed opening with tape or clean cloth so as not to allow foreign
matters to enter it.
Incidentally, do not forget to remove the covering tape or cloth in reassembly.
(4) When disassembling jointed parts, check whether set marks have been stamped or not, and stamp
set marks, if found necessary.
(5) On the major bolts, the cylinder No., bearing No., marking for incorporating position and set mark
have been stamped at the time of manufacture. However, they can not serve as reference for tight-
ening indefinitely because the clamping seat may be worn and the bolts may be stretched in their
use. Using a set mark only as a guide, be sure to tighten each bolt to the specified torque, speci-
fied angle or specified hydraulic pressure.
Chapter 9. Table of Tightening Torques of Major Bolts
Besides, when any of these major bolts has been replaced with a new one, give the same marking as
that of the former on to the new one.
(6) Note that bolts and nuts to be used a the high heated area are made of materials differed from
those used elsewhere but of the same size. If wrong ones are used in reassembly, they become
difficult to be taken out at the next servicing.
(7) When disassembling each section of the engine, carefully check the bolts and nuts that are not
exposed during a run. If such a bolt or nut is loose, investigate the cause, take the proper actions,
and then tighten it.
7-4
2001.6.15R
(Precautions at Completion&Handing for Turning Gear)
3) Precautions at Completion of Maintenance Servicing
(1) Turning the flywheel and lubricating oil priming, check for abnormalities in various parts of the
engine.
(2) Be sure to incorporate the removed covers such as covers for rotating parts, heat shielding covers
for exhaust pipe and protective covers for heated region in position.
(3) After having used the turning bar, return it on the set position.
(3) After having used the turning device, return it to the GEAR OUT state.
(4) Record the nature of maintenance servicing rendered and replaced parts in the Engine Log.
4) Handling Procedures for Turning Gear Device
(Optional spec.)
The turning device is of the gear intermeshing type
and equipped below the air motor on the operating
side. When the turning gear is intermeshing, the
engagement/disengagement switch is actuated,
disabling a start of the engine.
Handle the turning device according to the following
procedures:
Prepare the exclusive tools for turning.
Detach the lock bar, loosen the two stopper lock bolts, and then take off the stopper from the slot of
turning shaft.
Push in the shaft to the GEAR IN position.
Fit the stopper in the shaft slot , and tighten the two lock bolts.
Attach the socket for turning and ratchet handle to the shaft, and then turn the flywheel.
Before disassembling or checking any moving part engage the turning gear with the flywheel and lock
it with the lock bar to prevent self-rotation of crankshaft.
Ratchet handle 147673 - 92851
Socket (M24) 42111 - 001850
Air Motor
Turning Device
Drawing 7-1. Turning Device Equipped Point
7-5
(Handling for Hydraulic Jack)
1998.10.20R
After turning work, return the turning gear to the GEAR OUT position, fit the stopper in the slot , and
then tighten the lock bolts and lock bar.
Drawing 7-2. Turning Device Handling Procedures
5) Handling Procedures for hydraulic Jack
Use a hydraulic jack in a work of loosening or tightening the cylinder head tightening nuts and main bear-
ing cap tightening nuts.
Furthermore, simultaneously loosen or tighten the four cylinder head tightening per cylinder or two main
bearing cap tightening nuts per main bearing.
If the hydraulic fluid leaks while the hydraulic jack is being used, the fluid may spout under a high
pressure, resulting in injury. Therefore, be sure to observe the following precautions:
Do not use the hydraulic jack with a rubber hose having a flaw or an oil leaking portion.
Do not put nor drop a heavy thing on any rubber hose.
Do not grip any rubber hose. Do not bring your face close to the jack or branch during a work.
The lock bar is used to prevent the crankshaft from turning itself during an overhaul checking work.
Set the turning gear in the intermeshing state, lock the turning shaft with the stopper, and then tighten
the lock bar.
Look Bar
Look Bar
Flywheel
Turning Gear
GEAR IN
Pos.
GEAR
OUT
Pos.
Turning Gear Shaft
Stopper
Stopper Lock Bolt
Micro Switch
A
B
7-6
Use the following exclusive tools for loosening and tightening each nut.
[Usage]
(1) When assembling the hydraulic jack, be sure to use the sealing tape at the threaded part so that there
will be no leakage.
(2) Connect the hydraulic pump and branch with 3 m long rubber hose.
(3) Connect two 1 m long rubber hoses to the branch.
(4) Use the hydraulic pump placed horizontally.
(5) To operate the hydraulic pump, use it, opening the air valve.
(6) When a hydraulic jack is used for the first time, the rubber hose is filled with the hydraulic fluid. There-
fore, when the hydraulic pressure begins to rise, loosen the air vent plug of hydraulic pump, and then
checking the oil volume, replenish the hydraulic fluid.
(7) If the hydraulic jack does not work even though the hydraulic pressure has risen to the specified
value, loose couples will be the cause.
Loosen the relief valve of hydraulic pump to lower the hydraulic pressure, and then check the con-
nection of couples.
[ Common Tools ]
No. Exclusive Tool Description Qty.
Hydraulic pump 1
Connecting Piece 1
Gauge damper 1
Pressure gauge 1
Rubber hose, 3 m long 1
Branch 1
Rubber hose, 1 m long 4
Square elbow 2
Coupler, external
threaded
4
Coupler, internal threaded 4
Hydraulic jack 4
Spacer 4
Handle 1
To Branch
Relief Valve Air Vent Plug
Drawing 7-3(1/2). Hydraulic Jack Handling Procedures [Common Tools]
Body
O-ring
Piston
Back-up Ring
Back-up Ring
2003.7.11R
7-7
1998.10.20R
Drawing 7-3 (2/2). Hydraulic Jack Handling Procedures
[Cylinder Head Fitting Procedures] [Main Bearing Cap Fitting Procedures]
(1) Clean the surrounding of cylinder head (or main bearing cap) tightening nuts.
Tighten the cylinder head (or main bearing cap) tightening nuts to their seating with use of the handle.
(2) Fit the spacer.
When attaching the hydraulic jack to a cylinder head, be sure to check that the notch of the spacer
fitting surface does not make a contact with the adjacent cylinder head. Otherwise, the spacer and
the cylinder head will be damaged. Only then, raise the hydraulic pressure.
When attaching the hydraulic jack to a main bearing, direct the handle insertion hole toward the
crankshaft.
(3) Attach the hydraulic jack to the cylinder head (or main bearing cap) bolt, and screw in the jack until it
adheres to the spacer.
Make sure that there is no differences in level between the piston of hydraulic jack and the end sur-
face of body of the jack.
(4) Connect the hydraulic jack, branch and hydraulic pump with rubber hose (couplers).
Notch Notch Spacer
Spacer
7-8
1998.10.20R
(5) Loosen the hydraulic jack by one full turn from the state of adhering to the spacer.
Be sure to check that the notch of the spacer fitting surface does not make a contact with the adjacent
cylinder head. Otherwise, the spacer and the cylinder head will be damaged as the accurate tighten-
ing force would not be attained. Only then, raise the hydraulic pressure.
(6) Close the relief valve of hydraulic pump, and operate the pump lever to raise the hydraulic pressure to
the specified value.
(7) Insert the handle into the holes of the nut through the hole of spacer, and then turn the nut.
When disassembling, loose the nut by seven to eight holes.
When tightening, turn the nuts for three to four holes to the fully seated state.
If the nut to be removed could not be turned with use of the handle, slowly raise the hydraulic pres-
sure, and then turn the nut.
The hydraulic pressure should not be raised above 63.7 MPa (650 kgf/cm
2
).
When tightening, check if the nut threaded part is not damaged or the couplers are not poorly con-
nected in the case where the number of turns of the nuts is few.
(8) Gradually open the relief valve of hydraulic pump to decrease the hydraulic pressure to the zero.
(9) Screw the hydraulic jack in until it adheres to the spacer, and then discharge the hydraulic fluid from
the jack.
(10) Disconnect the rubber hose of hydraulic jack, branch and hydraulic pump.
(11) Remove the hydraulic jack and spacer.
When disassembling, check if the bolts are not loose after removing the tightening nuts.
When reassembling, check that set marks of the nuts and bolts are in agreement.
Specified hydraulic pressure: 58.8 0.5 MPa (600 5 kgf/cm
2
)
7-9
[Maintenance Servicing of Hydraulic Jack]
(1) To prevent rusting, apply the lubricating oil to the hydraulic jack, and store it.
(2) Cap each coupler not to allow foreign matters to enter it, and then store it.
(3) As for oil to be sent out from the hydraulic pump, use hydraulic fluid whose viscosity grade is ISO
VG32.
Table of Hydraulic Fluid Brands (Viscosity grade: ISO VG32)
SUPPLIER
General hydraulic fluid
Wear resistant hydraulic fluid
SHOWA SHELL
Tellus Oil C32
Tellus Oil 32
NIPPON MITSUBISHI OIL
Super Hiland 32
Super Hiland V32
COSMO OIL
Cosmo Epoch ES32
Cosmo Hydro AW32
JAPAN ENERGY ELF
JOMO Hydrax 32
JOMO Hydrax ES32
IDEMITSU KOSAN
Daphne Hydraulic Fluid 32
Daphne Super Hydro 32A
EXXON MOBIL
DTE Oil Light, Unipower 32
DTE 24 Oil, Unipower SQ32
[ ]
Brand
2001.10.R
7-10
7-1. Cylinder Head & Its Accessories
Carbon accumulated on the surface of cylinder head exposed to combustion gas hinders combustion and
allows scale to adhere on the cooling water passage, reducing the cooling effect.
Besides, the thermal load during running of an engine may cause the head combustion surface to be
cracked. Therefore, periodically overhaul and clean the cylinder head. (Simultaneously, also remove and
check its accessories.)
7-1-1. Cylinder Head
1) Disassembling preparation
Prepare the following exclusive tools:
(1) Hydraulic pump & hydraulic jack ....... One set
Chapter 7-0, 5) Handling Procedures for Hydraulic Jack (p.7-5)
(2) Cylinder head lifting tool
2) Disassembly
Disassemble the cylinder head according to the following procedures:
(1) Close each valve of cooling water inlet and outlet, and drain the cooling water from the cylinder jacket.
(2) Detach the exhaust manifold cover.
Using an eye bolt (P/#26610 - 120002), lift the cylinder head.
(3) Remove the exhaust manifold.
(4) Disconnect the following pipe and accessories from the cylinder head.
Overflow oil pipe, fuel injection pump pinion lub. oil pipe, cooling water connection pipe, pressure
indicator cock, fuel injection pipe joint, fuel injection pipe cap nut and fuel injection pipe.
(5) Detach the bonnet, and remove the rocker arm shaft pedestal, suction/exhaust valve guards and push
rod.
(6) Remove the fuel valve tightening nut.
(7) Remove the protective cap of a cylinder head bolt.
(8) Using the hydraulic jack, remove the cylinder head tightening nut.
Chapter7, 7- 0. 5) Handling Procedures for Hydraulic Jack (p.7-5)
Lifting tool body 146673 - 92310
Cap nut 146673 - 92320
Eye nut 26620 - 160002
Bolt 26116 - 160452

(Cylinder Head & Its Accessories)
7-11
Drawing 7-4. Cylinder Head Disassembling Procedures
(9) Lock the cylinder head lifting tool onto the fuel valve clamping bolt, and lift the cylinder head straight
up.
Lightly tighten the cap nut to an extent that the
body does not become rickety.
When lifting the cylinder head, be careful not to
damage the hydraulic jack fitting threaded part of
the cylinder head bolt.
(10) Removal of the fuel valve
Remove the cap nuts , eye nut and bolt
from the cylinder head lifting tool. Then,
attach the fuel valve drawing-out exclusive tool,
and draw out the fuel valve.
Attach the lifting tool body and drawing-out bolt
to the fuel valve guard. Tighten the nut to draw out
the fuel valve guard.
Drawing-out bolt 146673 - 92330
Nut 26732 - 160002

Fuel Injection Pump
Pinion Lub. Oil Pipe
Rocker Arm
Shaft Pedestal
Fuel Valve
Tightening Nut
Overflow
Oil Pipe Pressure
Indicator Cock
Bonnet
Push Rod
Suc./Exh. Valve
Guard
Cooling Water
Connecting Pipe
Fuel Valve
Clamping Bolt
Lifting Tool Body
Fuel Valve Guard
Drawing 7-5. Cylinder Head Lifting Procedures
Drawing 7-6. Fuel Valve Drawing-out Procedures
7-12
(11) Remove the valve rotators, cotters, valve springs, suction and exhaust valves.
The suction and exhaust valves use two cotters, respectively. In reassembly, fit the two cotters as
one pair to the valve to which the cotters have been previously fitted. (If not used the cotters as each
pair, an improper contact at the cotters may cause a breakage to the valves stem.
Taking care not to flaw the stem seal lip of a suction/exhaust valve guide, remove the suction and
exhaust valves, respectively.
Lock the cylinder head lifting tool body to the fuel valve clamping bolt with the cap nut . Remove a
valve rotator with the following exclusive tools.
Drawing 7-7. Valve Rotator Detaching/Attaching Procedures
For the maintenance servicing of fuel valve (disassembly, check, adjustment of fuel injection pres-
sure), refer to the following:
Chapter 6-3-5. Checking of Fuel Injection Valve & Adjustment of Injection Pressure
Rotator retainer 141616 - 92330
Handle support 146673 - 92360
Handle 139653 - 92340
Bolt 146673 - 92350
Nut 26706 - 120002

Valve Rotator
Valve Spring
Cap Nut
Lifting Tool Body
Fuel Valve
Clamping Bolt
7-13
(12) Disassemble the nozzle sleeve once every four years with use of the exclusive tool, check for corro-
sion in the water chamber side, and clean it.
Replace the packing and O-rings with new ones.
When incorporating the nozzle sleeve, apply Protec grease to the threaded part and packing seating
face, and tighten them to the specified torque.
After incorporating them, conduct the hydraulic test.
Drawing 7-8. Nozzle Sleeve Disassembling Procedures
3) Checking & servicing of cylinder head
After having removed the cylinder head, cover the cylinder so as not to allow foreign matters to enter
the boost air chamber.
Not to damage the threaded part of a cylinder head bolt, cap it with a protective tube.
Do not use any gas burner to eliminate carbon adherent on the combustion surface and at the
exhaust port.
The loose exhaust valve seat and a deteriorated O-ring may cause a water leakage.
Test pressure: 0.7 MPa (7 kgf/cm
2
)
Nozzle sleeve disassembling tool 146673 - 92250

O-ring
Nozzle Sleeve
Packing
7-14
(1) Check the state of carbon adherent in the combustion chamber and at the suction and exhaust ports
(for your reference on determining the intervals for subsequent servicing). After clearing, carefully
check for cracks and corrosion.
(2) Check the state of scale in the water jacket part. Depended on the water quality, a lot of scale adheres
even in the water jacket part of a fresh-water cooled engine. Therefore, at least once every two years,
clean the water jacket part with a descaling agent, etc. (For example, Unicon 146 sold by Yanmar can
descale the water jacket part without overhauling the cylinder head while the engine is stopped.)
(3) Especially carefully check for flaws and foreign matters in the socket and spigot part of the cylinder
head fitting surface. If this part has been flawed or contaminated by foreign matters, a blow-bye
occurs during a run.
(4) Conduct the hydraulic test at least once every two years, and check whether water leaks from the
exhaust valve seat mated part.
Also, if the cylinder head is overheated due to a failure of cooling water system, conduct a hydraulic
test.
4) Reassembly
Reassemble the cylinder head in the sequence revers to disassembly, paying attention to the following
points:
Replace each packing and O-ring with new ones. If you cannot avoid using a packing or an O-ring
again, sufficiently check it for no flaws, deformation and deterioration before using it.
Apply the lubricating oil on the suction and exhaust valves, attach the same cotters as those used in
the disassembly to the respective valves, and fit them while taking care not to damage the lip of a
valve guide stem seal.
If a head packing of the same dimensions as that used previously is used, the top clearance
becomes the standard value and does not require any particular adjustment.
Check for no foreign mattes in the suction and exhaust passages of cylinder head, piston upper part
and boost air chamber of cylinder, and then incorporate the cylinder head.
When mounting the cylinder head on the cylinder liner, take care not to flaw the threaded part of a
cylinder head bolt.
Apply the grease or lubricating oil on the hydraulic jack fitting threaded part of the cylinder head bolts
to prevent the treaded part from being rusted.
Apply the lubricating oil to the head tightening nut. After being tightened, cap them with the protec-
tive caps.
After incorporation of a cylinder head, adjust the suction/exhaust valve head clearance.
Chapter 6, 6-3-6. Adjustment of Suc./Exh. Valve Head Clearance
2
)
7-15
2003.9.10R
7-1-2. Suction & Exhaust Valves
Take care not to confuse the suction and exhaust
valves as they are of the same shape but made of
different materials.
1) Checking items
(1) Check for sulfuric acid corrosion and bend of the suction/exhaust valve stem, and measure the dimen-
sions.
If the clearance between the suction/exhaust valve stem and the corresponding valve guide exceeds
the usage limit value, replace either the valve or valve guide whichever is worn more than the other.
(2) Check for high-temperature corrosion of the valve poppet.
Correct the valve poppet tip part upon careful checking it because if it becomes too thin, it may be
chipped and the pieces may enter the combustion chamber and turbocharger, causing a secondary
damage. (However, do not grind the combustion surface side of the valve poppet part for this correc-
tion.)
(3) Check the state of blow-bye and carbon biting-in at the valve seat part, and according to the state,
grind the seat face.
(4) Measure the dimensions of the valve seat part. If the dimension have reached the usage limit values,
replace it.
(5) Check for cracks and corrosion of valve springs.
2) Suction/exhaust valve grinding
(1) Perform the initial valve grinding earlier than usual as indicated in Chapter 6, Table of Periodical
Checking. Judging the situation, determine the intervals of subsequent servicing.
(2) Checking the clearance between the valve guide and stem, replace the pertinent part, and then per-
form a valve grinding.
Chapter 10. Clearances & Wear Limits of Major Parts
(3) Apply the proper quantity of grinding compound to the valve to be ground, and elaborately grind the
valve with the specified grinding tool. Finally grind the valve with oil.
Drawing 7-10(1/2). Suc./Exh. Valve Grinding Procedures
Marking
1H37S12S1 S for suc. valve
1H3S12E E for exh. valve
W/Cr-plated stem
(M.D.O. spec.)
180AH3E E for exh. valve
(H.F.O. spec-nimonic)
Date of manufacturing
Step2: Tighten the nut 1/4 turns.
Step6: Loosen the nut 3/4 turns.
Step1: Make the nut free.
Step7: Fully tighten the nut (3/4 further after it is seated).
Step3: Tighten the bolts.
Suc. / Exh. Valve
Grinding Tool
Holder A
Holder B Suc. / Exh. Valve
Step4: Press the holder B.
Step5: Tighten the bolts.
Hold Down
Turn
Spring
Suc./Exh. Valve
Grinding Tool
Drawing 7-10(2/2).
Drawing 7-9. Markings for Suction&Exhaust Valve
7-16
(4) If a flaw on the seat face of a suction/
exhaust valve is so deep that it is
required to be corrected of the flaw by
grinding, finish grinding the valve seat
part in an angle shown in the figure at
right and the outer periphery of the
valve seat part makes contact with the
valve (poppet).
7-1-3. Suc./Exh. Valve Seat
The suction/exhaust valve seat has been shrink fitted to the cylinder head. The exhaust valve seat is of the
cooled type.
1) Checking & servicing
Do not use any gas burner to eliminate carbon adherent on the combustion surface and at the
exhaust port.
Otherwise, the exhaust valve seat may become loose or the O-rings may be deteriorated, resulting in
a water leakage.
(1) Check the state of blow-bye and carbon biting-
in of the valve seat part. According to the
state, grind the seat face. Since the satellite
has been built on the valve seat face, if a flaw
on it is so deep, correct it with use of a rough
correcting seat cutter (with grinder), and then
grind the valve seat part. (The seat cutter is
optionally available.)
(2) Check for water leakage at the exhaust valve seat mated part.
(If a water leakage is found, replace the valve seat.)
(3) Measure the contact diameter of the valve seat part. If the measurement exceeds the usage limit
value, replace the valve seat with a new one.
d
Valve
120
+30
0
120
0
- 30
120
0
- 30
Exhaust Seat
Suction Seat
Drawing 7-11. Angle of Suc./Exh. Valve Seat
Drawing 7-12. Valve Seat Correcting Procedures
(Rough Finishing)
7-17
2) Replacement of the valve seat
Replace the valve seat according to the following
procedures:
(1) Removal of the valve seat
Build up the whole circumference of the valve
seat face by arc welding to remove the valve
seat.
If the exhaust valve seat is difficult to remove
because of the O-rings incorporated in it, fur-
ther weld an iron plate to the valve seat, and
hammer out the valve seat through a round
rod driven into the valve guide.
(2) Incorporation of the valve seat
Check for flaws, hit mark and burr on the valve seat inserting hole of a cylinder head and on the
outer periphery of the valve seat. If found, correct it.
Measure diameter of the seat valve and the seat valve inserting hole, and confirm the interference.
[ Interference for the Value Seat ] (Unit: mm)
Heat the whole cylinder head to 40 to 60 . The appropriate heating is by steam cleaning.
Chill the valve seat with liquid carbon dioxide. If liquid carbon dioxide is not available, soak it in the
mixed solution of a small lump (10 kg) of dry ice and alcohol (1.5 lit.) for 1 hour or longer to chill it.
Chill the exhaust valve seat with O-rings incorporated to it. Do not use liquid nitrogen. Otherwise, the
O-rings will be hardened and broken when the valve seat is inserted in the cylinder head.
Just before inserting the exhaust valve seat
into its hole of the cylinder head, apply the
seizure inhibitor (spray) and silicone-based
liquid packing (Three-Bond 1211 or its
equivalent) to the inserting hole.
Suction valve seat 0.045 0.095
Exhaust valve seat
0.039 0.072 (59part)
0.069 0.102 (67part)
Arc Welding
Iron Plate
Valve Seat
Drawing 7-13. Valve Seat Removing Procedures
Liquid Packing
: Seizure Inhibitor (spray)
Drawing 7-14. Exhaust Valve Seat Inserting Procedures
2003.9.10R
7-18
Drawing 7-16. Valve Guide Removing Procedures
Using the suction valve (or exhaust valve), rapidly
insert the valve seat into its hole on the cylinder
head.
Take care not to tilt the valve seat. Apply a load
for one to two minutes on the valve seat to avoid
insufficient adhesion to its inserting hole.
After having replaced the exhaust valve seat, be sure to conduct the hydraulic test to make sure no
water leaks from the mated part.
7-1-4. Suc./Exh. Valve Guide
The suction/exhaust valve guide has been shrink fitted and inserted and incorporated with the stem seal.
(1) Measure the clearance between the suction/
exhaust valve guide and the valve stem. If
the measurement exceeds the usage limit
value, replace the valve guide or valve.
(2) Replace the stem seal at every servicing.
2) Removal of the valve guide
Draw out the suction/exhaust valve guide by ham-
mering it from the valve side through a stepped
doubling rod.
3) Incorporation of the valve guide
Chill the valve guide with liquid nitrogen, liquid carbon dioxide or the like, and then press fit it.
When press-fitting the valve guide, hold the flange part of the valve guide.
2
)
Interference: 0.001 0.035 mm
Drawing 7-15. Valve Seat Inserting Procedures
INSERT
Valve Seat
Doubling Rod
HAMMER
24
7-19
4) Incorporation of the stem seat
Incorporate the stem seal with use of a jig so as not to damage the stem seal lip.
7-1-5. Suc./Exh. Valve Bridge & Its Guide
The valve bridge guide has been shrink fitted in the cylinder head.
If the engine is used under the condition that there is an excessive clearance between the valve bridge and
valve bridge guide, the valve bridge may fall while the suction/exhaust valve is working, causing a malfunc-
tion of the valve, uneven wear of the valve guide or damage of suction/exhaust cam.
If the clearance between the valve bridge and valve bridge guide exceeds the usage limit value, replace
either the valve bridge or valve guide whichever is worn more than the other.
2) Replacement of the valve bridge guide
Chill the valve bridge guide with liquid nitrogen or liquid carbon dioxide, and then press fit it into the cylin-
der head.
7-1-6. Valve Rotator
Improper rotation of the valve rotator will cause carbon to be bitten in the valve seat part, causing blow-bye
at the seat part and affecting the service life of the valve and valve seat. Therefore, periodically overhaul
and check the valve rotator.
To take out the valve rotator without disassembling the cylinder head, set the piston at the T.D.C. of
the compression stroke, and then remove the valve rotator.
Drawing 7-7. Valve Rotator Detaching/Attaching Procedures (p.7-12)
Remove the circlip, and check each part. If any of
the following defective parts is found, replace it.
Wear (at the body groove) and corrosion of
Belleville spring
Wear (deformation) and corrosion of ball
Wear and breakage of coil spring
Wear of the body groove
Body
Belleville Spring
Coil Spring
Spring Shoe
Circlip
Ball
I
I
View I-I
A
Drawing 7-17. Valve Rotator
7-20
2) Incorporation
Incorporation the coil springs, balls and Belleville spring in the proper direction.
After incorporation, make sure of the clearance .
7-2. Piston & Connecting Rod
The frequency of piston drawing-out check varies according to the daily maintenance, especially the lubri-
cating oil control and load (overload and excessively low load). Therefore, the supervisor is required to
decide the proper frequency. However, the initial overhaul and check should be performed at the time men-
tioned in Chapter 6. From then on, decide the subsequent check schedule according to the overhaul
checking results, an increase of blow-by and an increase in lubricating oil consumption. When the lubricat-
ing oil consumption has become twice the initial value, overhaul and clean the piston, and replace the pis-
ton rings.
7-2-1. Piston & Piston Pin
Prepare the following exclusive tools:
[For Disassembling the Connecting Rod Bolt]
[For Disassembling the Protection Ring]
Socket wrench for connecting rod bolt 146673 - 92850
Handle 138987 - 92760
Lock nut 239653 - 92770
Drawing-out plate, protection ring 146673 - 92060
Liner drawing-out upper implement 146673 - 92010
Spacer 139653 - 92040

Eye bolt, piston lifting 26610 - 120002
(Piston & Connecting Rod)
2006.1.20R
7-21
2) Piston drawing-out
While you are drawing out or incorporating the piston, the crankshaft may turn spontaneously due to
the unbalance. This is dangerous. Securely lock the flywheel not to allow the crankshaft to turn. Mak-
ing sure the crankshaft does not turn spontaneously, proceed to a work.
Chapter 7-0, 4) Handling Procedures for Turning Device (p.7-4)
(1) Set the piston at a position of about 80 to 90
before the T.D.C.
(2) Place the protection ring drawing-out tool on
the piston.
Place the tool so that its outer taper faces toward
the piston and do not allow it to make contact with
the cylinder liner.
(3) Install the liner drawing-out upper implement
and spacer in the cylinder block as shown in
Drawing 7-18. Afterwards, fix the tools with the
cylinder head tightening nut.
(4) Turn the flywheel, and remove the protection ring.
(5) Remove the disassembling tools and protection ring.
(6) Eliminate the carbon from the upper part of cylinder liner.
(7) Set the piston at a position of about 30after the T.D.C.
(8) Loosen the connecting rod bolts with the specified disassembling tool, and then remove the bolts and
metal cap.
(9) Screw the lifting eyebolt into the piston, and lift it by 20 to 30 mm.
(10) Remove the upper metal, and draw out the piston.
Take care to prevent the connecting rod from making a contact with the crankshaft or cylinder liner.
3) Removal of the piston pin & piston rings
(1) Remove the piston pin circlips with use of pliers (P/#28190 - 000130).
Note that the circlip springs out to cause an injury if the tip of pliers come out of the groove of circlip in
course of removing the circlip.
Cyl. Head
Tightening Nut
Protection Ring
Tapered
Part
Drawing 7-18. Protection Ring Drawing-out Procedures
2006.1.20R
7-22
2001.2.28R
(2) Draw out the piston pin while holding the connecting rod.
(3) Make two loops from wire, and then remove a piston ring with them.
Wear gloves because the corners of rings will be sharp edged to cause you an injury after a long time
of run.
Be careful not to widen the cut of a ring by more than 40 to 50 mm; otherwise, the ring may be bro-
ken.
Check the state of carbon adherent on the piston and the state of wear various parts. Refer to these check-
ing results in deciding the subsequent check schedule.
In cleaning of the piston, do not sandpaper the pis-
ton skirt which has been provided with special coat-
ing. (Washing the piston with a carbon removing
agent such as Unicon 146 and Neos is recom-
mended.)
(1) Check the contact of piston skirt and piston hole.
(2) Check the piston by Penetrate Testfor cracks
on its top surface and ring groove (outside &
inside).
(3) Remove the piston cooling case cover, and check
for adherent scale.
(4) Measure the dimensions of various piston parts
and of the piston pin.
(5) If possible, replace the piston rings with new
ones, considering the time to the next servicing.
(6) If the piston is replaced with the new one, provide
the same set mark on the new one as that on the
previous one.
5) Incorporation of the piston
Incorporate the piston in the sequence reverse to
drawing-out, paying attention to the following points:
(1) Incorporate the perforated piston cooling case
cover on the operating side, apply a proper
screw lock agent (Tokyo Three-Bond Screw Lock
No.1 or its equivalent) on the bolts, and tighten
them to fix the cover.
(2) Incorporate the piston pin circlip with its opening
facing straight down.
(3) Incorporate the piston rings with their marked
sides facing upward and their cuts shifted 120
from those of adjacent rings.
Penetrate Test for Cracks on Piston
Piston Set Mark Marking on Ring
Circlip Opening
Set Mark
Cut
Coil Joint
Piston Cooling Case Cover
(Perforated)
T
T
2T
Drawing 7-19.
Drawing 7-20. Piston Incorporating Procedures
7-23
2002.5.15R
Piston ring groove plating repaired piston.
If the piston top ring groove have been repaired with Cr-plating, do not use the 3-face Cr-plated top
ring.
(4) Incorporate the oil ring with its coil joint shifted 180from its cut.
(5) Incorporate the piston and connecting rod, aligning their set marks with each other.
Do not apply the lubricating oil on the rear of crank-pin metals.
(6) Apply the lubricating oil to the piston, cylinder liner and crankshaft.
(7) Set the piston inserting guide (P/#146673 - 92140),
and incorporate the piston.
(While tapping the piston with a resin hammer,
drive the piston down.)
(8) Tighten the connecting rod bolts.
If you have restamped the set mark on a connecting
rod bolt, do not mistake the new set mark for the pre-
vious set mark.
Chapter7, 7-2-4. Connecting Rod Bolt (p.7-24)
7-2-2. Connecting Rod
(1) Check the contact and looseness in fit of piston-pin metals.
(2) Measure the inner diameter of a piston-pin metal. If the measurement exceeds the usage limit value,
replace the piston-pin metal. Remove the piston-pin metal either by hammering it out through a dou-
bling metal or by drawing it out with a press so as not to flaw the metal inserting hole.
To incorporate the piston-pin metal, align oil holes and press fit the metal. After having press fitted,
measure the inner diameter of the metal.
(3) Check for cracks and wear on the serration mating surface of the connecting rod big end.
If a water hammer has occurred or a heavy burnout of the piston has been detected, measure the
bend and inclination of the connecting rod, and dye check for cracks.
Criteria for simple bend check
Draw out the piston-pin metal, detach the oil hole plug on the small end, and try to insert a 10-mm dia.
bar or long drill into this plug hole and to turn the bar or drill.
If the connecting rod is bent, the bar or drill cannot be inserted, or it can be inserted but cannot be
turned.
Piston inserting Guide
Drawing 7-21. Piston Reassembling Procedures
7-24
2003.9.10R
7-2-3. Crank Pin Metal
(1) Check the contact on the rear and mating
surface of each metal, and also check for
cranks, seizure and imbedded foreign mat-
ters on the sliding surface of each metal.
(2) Incorporate the crank-pin metals to the con-
necting rod, and tighten the connecting rod
bolts to the specified angle. Then, measure
the inner diameter of the metals. If the mea-
surement exceeds the usage limit value,
replace the metals.
(3) Measure the thickness of the upper and
lower metals. If the difference between the
dimensions & and the dimensions &
is 0.04 mm or more, replace the metals.
(4) When incorporating the metals to the connecting rod, clean them not to allow biting-in of foreign mat-
ters. Moreover, do not apply the lubricating oil the rear of the metals.
7-2-4. Connecting Rod Bolt
(1) Checking for hit mark and plucking on the bearing surface and threaded part of each bolt. If any defect
is found, correct it.
(2) When disassembling a connecting rod, be sure to restamp the set mark which has been stamped
on each connecting rod bolt just before the shipment from our shop because the tightening torque
of the bolt varies as depended on accustoming of the bolt threaded part and bearing surface and
the big end serration mated surface.
(3) To prevent the bolts from being broken due to fatigue, replace them about every 20,000 hours even if
their appearance is normal.
Be sure to replace both the upper and lower crank-pin metals as a pair.
Approx. 40mm
Approx. 40mm
B
A
C
Drawing 7-22. Metal Thickness Measuring Points
7-25
1999.6.25R
2) Reassembling procedures
(1) Be sure to incorporate the bolts at the respectively previous positions.
(2) Before tightening the bolts, apply the lubricating oil to the treated part and Protec grease to the bear-
ing surface.
(3) Tighten the upper and lower bolts gradually in the three steps (approx. 40, 80and 120), aligning
with the set mark to the point on the connecting rod.
Keep the deviation between the set mark of the bolt and the set mark of the connecting rod in less than
2 mm in the bolt tightening direction.
3) Bolt set mark stamping procedures
The connecting rod bolts are tightened to the specified angle. On the connecting rod, the marks indi-
cating the specified angle (120) are stamped (at two points & ).
Stamp a set mark on each bolt according to the following procedures under the condition that the
crank-pin metals are not equipped.
(1) Apply the lubricating oil and Protec grease to each bolt, and screw it to its seating by hand.
(2) Using a torque wrench, tighten the bolt to the seating torque.
After replacing connecting rod bolts or the connecting rod, repeat tightening the bolts by about 90
and loosening them three or four times to make the bolts and the connecting rod accustomed each
other.
(3) Stamp a temporary set mark on the side of the
bolt collar, aligning with the set mark at the
point on the connecting rod.
(4) Tighten the upper and lower bolts gradually in
the three steps (approx. 40, 80and 120),
aligning with the set mark to the point on the
connecting rod.
(5) Stamp a set mark on the side of the bolt collar,
aligning with the set mark at the point on the
connecting rod.
After replacing connecting rod bolts and the con-
necting rod, stamp the same Cylinder No., Bolt
No., etc. as those stamped on the previous ones.
Seating torque: 49 Nm (5 kgf m)
B
120q
B
120q
B
Temporary
Set mark
Set mark
Set mark
Drawing 7-23. Connecting Rod Bolt Marks
7-26
7-3. Cylinder Block & Cylinder Liner
7-3-1. Cylinder Block
Excluding some special case such as burnout of the crankshaft, ordinarily removal of the cylinder block is
not necessary. When the cylinder head, piston, cylinder liner, etc., are removed, perform the following
check and servicing:
1) Checking and servicing
(1) Check for loose cylinder head bolts and main bearing cap clamping bolts.
Drawing 7-24. Cylinder Block Checking Points
(2) Clean the boost air chamber. If the rust preventive paint applied on its inner surface has peeled off,
repair it. (Epoxy resin paint: Nippon Paints Hi-Pon 50 or its equivalent)
(3) Clean the water jacket and cylinder liner fitting part, and check for corrosion.
7-3-2. Cylinder Liner
Periodically measure the inner diameter of cylinder liner because the extent of wear of inner surface of
cylinder liner varies as depended on the control on lubricating oil used, cooling water temperature and
normal load.
Periodically draw out the cylinder liner, and check for corrosion of cylinder liner because cooling water
may cause cavitation at the cylinder liner water jacket and erode from the outer surface of cylinder liner.
When replacing a bolt with damaged thread...
Apply a seizure inhibitor (Sumitomo Metal Minings Low Call Spray or its equivalent) to the
threaded part on the studded side, and incorporate the new bolt.
Studding torque: 196
+49
0
N m (20
+5
0
kgf m)
Incorporate the O-ring on the studded side, and apply white paint.
If a main bearing metal has been burnt out, measure the accuracy of main bearing cap hole.
Straightness: 0.03 mm or less in 1 mm of length
Roundness: 0.02 mm or less
Measure the inner diameter of cylinder liner under the condition of being incorporated in the cylinder
block and with use of the inner diameter position measuring implement (P/#42111-002930).
O-ring
Boost
Air
Chamber
(Cylinder Block & Cylinder Liner)
2003.9.10R
7-27
(2) When drawing out the cylinder liner, cover the crankshaft with a sheet or the like to prevent water and
foreign matters from entering the crankcase.
2) Disassembly
Remove the cylinder liner according the following procedures:
(1) Attach the exclusive tools in the ascending order of numerals shown in Drawing 7-25.
(2) Adjust the length of protrusion from the lower part of the drawing-out bolt to about 60mm, and lock
the drawing-out bolt with the lock nut .
(3) While supporting the cylinder liner to prevent it from making contact with the cylinder, tighten the nut .
(4) Fit the cylinder liner in the stepped part on the lower side of the upper implement , and lock the cyl-
inder liner with the drawing-out tools.
(5) Attach a wire rope to the upper implement , and lift the cylinder liner.
Drawing 7-25. Cylinder Liner Drawing-out Procedures
Spacer 139653-92040
Liner drawing-out upper

implement
146673-92010
Bolt 137655-92030
Washer 22137-240000
Nut 26732-240002
Liner drawing-out lower

implement
146663-92020
Nut 26732-240002
Lock nut 26772-240002

Attach the aforementioned upper implement and the lower implement so that their respective
stepped parts face the inner diameter side of the cylinder liner and the lower implement in the
direction of the crankshaft.
Abt. 60mm
2003.7.11R
7-28
Do not use sand paper, wire brush, or the like when cleaning the outer periphery of cylinder liner. Oth-
erwise, the heat-treated layer on the surface is removed to cause rusting or corrosion.
(1) If the measurement on the inner diameter of a cylinder liner exceeds the usage limit value or if the
measurement is expected to reach the usage limit value before the next servicing, replace such a cyl-
inder liner.
(2) Check for seizure, streak and corrosion on the sliding surface of cylinder liner.
(3) Dye check the rounded part of collar of cylinder liner for cracks.
(4) Check for corrosion and wear at the part of cylinder liner mated with the cylinder block.
4) Reassembly
(1) Replace the O-rings of cylinder liner. Apply the lubricating oil or silicone oil to new O-rings, and fit
them. Then, eliminate torsion from the O-rings.
Before incorporating the O-rings, stretch them to check whether a crack has developed or not on their
surface due to a change of temperature and humidity, for instance, with time if stored under improper
condition.
(2) Just before incorporating the cylinder liner, apply the silicone-based liquid packing (Three-Bond 1211
or its equivalent) to the upper section of cylinder block. Moreover, apply the lubricating oil to the
mated part of the cylinder liner and block.
(3) Attach the aforementioned exclusive tools thru to the cylinder liner. Then, aligning the mark
0 (zero) of the cylinder liner and the punched mark of the cylinder (block), incorporate the cylinder
liner into the cylinder, block. (Do not use the spacer for this incorporation.)
After having overhauled and serviced the cylinder liner, check for a water leakage form the O-ring part
when filling the water tank with cooling water and when running the engine for testing.
Drawing 7-26. Liquid Packing & Lub. Oil Applying Points
Liquid Packing
Lub. Oil
Lub. Oil
7MAINTENANCE SERVICING
7-29
7-4. Main Bearing & Crankshaft
Each throw of the crankshaft is equipped with two balance weights of which shape varies with the service
rotatory speed of a machine driven by the engine.
At the timing gear case behind the journal for the No.1 cylinder, another main bearing is mounted, and fur-
ther at the head, a thrust bearing is incorporated. Thus, this crankshaft is equipped with eight bearings in
total.
The main bearing cap is of the suspension metal structure fixed to the cylinder block with two clamping
bolts (with the tightening nuts tightened to the specified hydraulic pressure) and two side bolts (tightened to
the specified torque).
Side bolts
The side bolts for the datum part (No.0) main bearing cap are equipped only on the non-operating
side. To the No.1, 2, 6 & 7 main bearing caps, side bolts of different lengths are provided to clamp
also the engine supporting feet.
Drawing 7-27. Main Bearing Numbers
7-4-1. Main Bearing
Any main bearing cap cannot be taken out through the cylinder side cover. Check or replace a main bear-
ing metal from the operating side according to the following procedures:
[For the hydraulic pump & hydraulic jack type]
Chapter7, 7-0. 5) Handling Procedures for Hydraulic Jack (p.7-5)
Cyl. No. No.6 No.5 No.4 No.3 No.2 No.1
7
71
72
6
61
62
5
51
52
4
41
42
3
31
32
2
21
22
1
11
12
0
01
02
Main brg. cap No.
Tightening nut
stamped No.
On the op. side
On the non-op. side
(Main Bearing & Crankshaft)
7-30
[Main Bearing Cap Drawing-out Implement]
[Main Bearing Cap Holding Implement]
[Upper Metal Detaching/ Attaching Implement]
(2) To facilitate the check or replacement work, set the piston adjacent to the main bearing to be disas-
sembled at a position about 120before the T.D.C.
2) Disassembly
(1) Fit a hydraulic jack, and connect it with a hydraulic pump.
Take out t the rubber hose in a direction to facilitate the work.
Drawing 7-28. Hydraulic Jack Fitting Procedusres
Chapter7, 7-0. 5) Handling Procedures for Hydraulic Jack (p.7-5)
Body 146673-92100
Mounting bolt (M10 60) 26206-100602
Drawing-out bolt 26206-121554
Nut 26706-120002
Bolt 146673-92120
Circular nut 146673-92110

Upper metal detaching/

attaching pin
146673-92970
Upper metal inserting

implement
146673-92950
120q
Direction of Rotation
Side Bolt Side Bolt
7-31
(2) Remove the side bolts from the main bearing to be disassembled.
(3) Loosen the main bearing cap clamping nuts, applying the hydraulic pressure to the hydraulic jack.
If the main bearing cap cannot be drawn out due to its own weight:
Loosen the side bolts of the adjacent main bearing caps.
Loosen the main bearing cap tightening nuts two to three turns, and then draw out the main
bearing cap using the drawing-out tools.
Lock the drawing-out tool body to the main bearing cap bolts with the bolts . Then, screw the
bolt to the main bearing cap, and turn the nut to draw out the main bearing cap.
(4) Remove the main bearing cap tightening nuts, and attach the main bearing cap holding implement to
the main bearing cap clamping bolts.
Drawing 7-29. Main Bearing Cap Drawing-out Procedures
Do not remove both tightening nuts simultaneously. Otherwise, the main bearing cap may fall,
resulting in injury.
Screw each circular nut into the corresponding holding bolt to lock the holding bolt with the corre-
sponding main bearing cap clamping bolt. Adjust the position of circular nuts to make them hold the
main bearing cap.
Drawing 7-30. Main Bearing Cap Holding Procedures
7-32
(5) Remove the main bearing lower metal.
(6) Remove the upper metal.
Fit the attaching/ detaching pin to the crankshaft oil hole from the no-operating side (so that the
head of attaching/detaching pin lies along the outer periphery of crankshaft). Slowly turn the fly-
wheel in the direction of engine rotation, and draw out the upper metal to the operating side.
Disassembly & Reassembly of No.0 bearing cap
Thrust metals are equipped on both the front and the rear of the datum part (No.0) main bearing cap.
Remove the lub.oil pump and side bolt on the non-operating side first, and then disassemble the
No.0 bearing cap in the same way as for the No.1 thru 7 main bearing caps.
Drawing 7-31. Metal Drawing-out Procedures
Carefully check and service the main bearing metals. If the clearance between the crankshaft and
the main bearing metals becomes too large, the lubricating oil pressure drops to burn out the metals
and increase the deflection of crankshaft, possibly resulting in serious accidents such as a breakage
of the crankshaft.
(1) Check for hit marks and flaws on the mated and fitted surfaces of main bearing cap with and to the
cylinder block.
(2) Check for hit marks on the mating surface and rear of the main bearing metal, and also check for
flaws, seizures and imbedded foreign matters on their sliding surface.
Do not correct the rear and slicing surface of any main bearing or thrust metal because such a
corrective repair changes the clearance between the metal and the crankshaft.
Drawing 7-32. Thrust Metal Fitted State
Notch (pawl) Notch (pawl)

Upper Metal, therust
Lub. Oil Pump
Side Bolt
Lower Metal, therust
7-33
(3) Check for looseness of main bearing cap clamping bolts.
Studding torque: 196
+49
0
N m (20
+5
0
kgf m)
(4) Measure the clearance between the crankshaft and the metal.
An accurate method of measuring the clearance is to remove the crankshaft and then to mea-
sure its outer diameter and the inner diameter of a main bearing cap.
To obtain the clearance without removing the crankshaft, place and about 0.5-mm dia. lead wire
on the sliding surface of main bearing lower metal (along the outer periphery of crankshaft to
prevent the lead wire from slipping with grease, etc.), tighten the main bearing cap tightening
nuts to the specified hydraulic pressure, take out the lead wire, and then measure its thickness.
You can determine the clearance between the crankshaft and metal from this thickness.
(5) If the clearance exceeds the maximum allowable value due to wear of the metal, replace it with the
new one.
When replacing the metal, be sure to replace both the upper and lower metals as a pair.
If the crankshaft is excessively worn (unevenly worn), replace the metals with undersized metals.
Also, it is necessary to rework the crankshaft by polishing it so that it fits with the new undersized metals.
[Thrust metals]
(1) Check for wear and burnout.
(2) If the clearance exceeds the maximum allowable value due to wear, replace both the upper and lower
metals as a pair.
Drawing 7-33. Thrust Clearance Measuring Procedures
Fix the dial gauge stand to the cylinder block. Put the dial gauge in contact with the crankshaft.
Then, move the crankshaft forward to set the indication of the gauge to zero.
Move the crankshaft backward. Then, read the value indicated by the gauge. The indicated
value is the thrust clearance.
Crank Shaft
Thrust Metal
Dial Gauge
7-34
(3) When incorporating thrust metals, observe the following points:
Incorporate each one of the upper and lower metals of the frontal and rear parts at the respective
former point, not mistaking one for other.
Incorporate the upper metal by mating its printed part with the cylinder block side and sliding it
along the crankshaft.
Incorporate the lower metal, mating its groove with the crankshaft side.
4) Incorporation of main bearings
Reassemble main bearings in the following sequence:
(1) Turn the flywheel to lower the oil hole in the crankshaft below the center of crankshaft.
(2) Directing the pawl of the upper metal toward the non-operating side, insert the upper metal along the
crankshaft.
Drawing 7-34. Upper Metal Incorporating Procedures
Position the upper metal in the forward-backward direction so that its pawl will mate with the pawl
hole in the cylinder block.
(3) Attach the upper metal inserting implement to the main bearing cap (from which the lower metal is
detached).
Attach the implement, mating its one curved end with the outer periphery of a main bearing cap
clamping bolt on the operating side and aligning the other stepped end with the inner periphery (on
the pawl hole side) of main bearing cap.
(4) Insert the attaching/ detaching pin to the crankshaft oil hole on the non-operating side.
Put the head of metal attaching/ detaching pin along and in close contact with the outer periphery of
crankshaft with the proper grease so as not to allow the pin to fall during turning.
(5) Tighten the circular nuts of the main bearing cap holding implement until the upper metal inserting
implement is about to make contact with the rear of the upper metal.
Rounded End Stepped End
Main Brg. Cap
Clamping Bolt
Pawl Hole
Pawl Hole
Pawl
Non-operating Side Operating Side
7-35
(6) Slowly turn the flywheel in a direction reverse to the direction of engine rotation.
Make sure the side of pawl of the upper metal is in contact with the side of the metal inserting imple-
ment. If they are not in contact, the pawl does not fit in the pawl hole.
(7) When the pawl of the metal has been aligned with the pawl hole in the cylinder block, continue turning
the flywheel until the metal end aligns with the cylinder block end.
(8) Loosen the circular nuts to lower the main bearing cap. Remove the metal attaching/ detaching pin
and metal inserting implement . Then, incorporate the lower metal.
(9) Tighten the circular nuts and remove the holding bolts . Then, fit main bearing cap tightening
nuts.
Fit the tightening nuts one side a time. When a main bearing cap falls under its own weight, there is a
fear you might be injured.
(10) Tighten the nuts until the main bearing cap makes a close contact with the cylinder block.
If the side bolts of main bearings adjacent to the main bearing involved in disassembly have been
loosened, first tighten the side bolt on the non-operating side, and then the side bolt on the operat-
ing side to the specified torque.
(11) Tighten the side bolt on the non-operating side to half of the specified torque. (Have the bolt on the
operating side removed in advance.)
(12) Tighten the side bolt on the operating side to its seating by hand.
(13) Tighten the main bearing cap tightening nuts to the specified hydraulic pressure.
(14) Tighten the side bolt on the non-operating side to the specified torque.
(15) Tighten the side bolt on the operating side to the specified torque
After incorporating the main bearing, measure the crankshaft deflection.
Chapter 6, 6-3-17. Measurement of Crankshaft Deflection (p.6-34)
7-36
7-4-2. Crankshaft
The crankshaft requires careful checking and measurement because it may be broken or burnt out if you
continue running under the following states of crankshaft:
Uneven wear of crankshaft
Excessive clearance between the crankshaft and main bearing metal due to wear of crankshaft
Running exceeding the allowable value of crankshaft deflection
Running at critical region of torsional vibration rotatory speed.
1) Disassembling procedures
In either case of removing the crankshaft downward by lifting the engine or removing the crankshaft up
ward by inverting the engine, fit the rope to the No.2 & 5 crank-pin parts, and remove the crankshaft verti-
cally. (The engine lifting tool is optionally available.)
2) Checking & measurement
(1) Check for flaws, improper contact and abnormal wear of the bearings.
(2) Dye the root rounded part of crank arms.
(3) Check for looseness of balance weight clamping bolts.
(4) Measure the dimensions of bearings and check for uneven wear.
(5) Measurement of crankshaft deflection
For measuring procedures, refer to the following:
Chapter 6, 6-3-17. Measurement of Crankshaft Deflection
Drawing 7-35. Crankshaft Bearing Part Measuring Points
In a burnout of the crankshaft bearing part, not only the correction and replacement o main bearing or
thrust metals but also check for hair cracks through measurement of the surface hardness and mag-
netic flaw detection.
Crank shaft surface hardness Should be HS 65 85.
Hair crack Should not be detected.
7-37
7-5. Timing Gear, Camshaft & Suc./Exh. Swing Arm
7-5-1. Timing Gear
Even under the condition of normal operation, there is a wear of gears. This may cause a pitching wear,
plucking and hair cracks on the tooth surface.
Besides, since the wear is related to noise and vibration periodically check the backlash of gears and con-
tact of tooth surface.
When disassembling the timing gears, measure the backlash of gears, If the measurement exceeds the
allowable value, replace the pertinent gear of bearing with the new one.
A set mark is stamped on the side of crank gear, idle gear A, idle gear B and cam gear. When assembling
the timing gears, set the No.1 (or No.6) cylinder at the B.D.C., and align the set marks.
Drawing 7-36. Timing Gear Set Marks Drawing 7-37. Cam Gear Disassembling Procedures
1) Cam gear
The governor drive bevel gear is incorporated to the cam gear, and they are incorporated to the
camshaft together with the tachometer drive coupling.
Disassemble (or reassemble) the cam gear according to the following sequence with the cover of timing
gear case removed:
(1) Remove the governor and governor driver.
(2) Remove the tachometer drive shaft.
(3) Remove the cam gear clamping bolt and tachometer drive coupling.
(4) Draw out the cam gear toward the flywheel side, and remove the gear through the window of timing
gear case.
Gov. Drive Bevel Gear
Cam Gear
Set Mark
Idle Gear B
Idle Gear A
Crank Gear
Governor
Governor Driver
Gov. Drive Bevel Gear
Cam Gear
Tachometer Drive Coupling
Tachometer Drive Shaft
Idle Gear A
Idle Gear B
(Timing Gear)
7-38
(Timing Gear)
(5) Cam gear clamping procedures
Mating the number stamped on the head of cam gear clamping bolt with the number stamped on
the side of cam gear, incorporate the bolt into the gear.
When tightening the cam gear clamping bolt, apply the seizure inhibitor (Three-Bond 1910 or its
equivalent) on the bearing surface and threaded part of the bolt, and then tighten the bolt to the
specified torque.
2) Idle gears
Extract the idle gear mounting shaft toward the flywheel side, and then take the idle gears out from the
window of timing gear case.
Drawing 7-38. Idle Gears Disassembling Procedures
(1) Remove the flywheel.
(2) Remove the idle gear mounting shaft support.
(3) Extract the idle gear mounting shaft toward the flywheel side.
(4) Checking
Check for seizure and uneven wear of idle gear shaft bearing and mounting shaft, and measure the
dimensions, If the bearing clearance exceeds the allowable value, replace the bearing or mounting shaft.
(5) When reassembling the idle gear assembly, replace the O-ring of the idle gear mounting shaft.
3) Crank gear
(1) To facilitate removal of crank gear, drill a hole
below the bottom land of the gear, and drive a
chisel into this hole. This will loosen fitting, and
thus the gear can be easily removed.
Take care not to damage the positioning knock pin.
(2) Before incorporating the crank gear, put it in the oil bath, and hear the bath to about 150 to 190 ,
leave the gear in the bath for about 60 minutes, and then take it out of the bath. After that, quickly
insert the crank gear to the crankshaft.
Refrain from heating the crank gear with a burner or the like, otherwise the temperature will rise
excessively to change the structure of the material and to decrease its strength. Instead, use of an oil
bath is recommended for this purpose.
The idle gears A & B have been shrink fitted.
Idle Gear
Mtg. Shaft
Support
Idle Gear
Mtg. Shaft
Flywheel
O-ring
Hammer
Chisel
Drilled Hole
Crank Gear
Drawing 7-39. Crank Gear Removing Procedures
7-39
7-5-2. Camshaft
The fuel cam and suction and exhaust cams form a monoblock structure with the camshaft. The camshaft
is split in two at the bearing part between the No.3 & No.4 cylinders and coupled by reamer bolts.
If the engine installation site does not have space enough to extract the camshaft in one piece, split it, and
then draw out two parts from the engine.
Draw out the camshaft toward the front side (the side opposite to the flywheel).
1) Disassembly
Disassemble the camshaft according to the following procedures:
(1) Remove the bonnet, and then rocker arm shaft pedestal and push rod.
(2) Disconnect the fuel injection pipe joint, and then remove the fuel injection pump and fuel injection
pump driver.
(3) Remove the suc./exh. swing arm.
For their removing procedures, refer to the following:
Chapter 7-5-3. Suc./Exh. Swing Arm (p.7-40)
(4) Remove the cooling water pump, fuel oil feed pump and fuel oil filter (together with its mount).
(5) Remove the gear case.
Lift the gear case up with rope. If the gear case falls, an accident may occur.
Since the gear case is positioned with two knock pins, jack it up with M12 bolts to remove it.
(6) Remove the cam gears.
For their removing procedures, refer to the following:
Chapter 7-5-1, 1) Cam gear (p.7-37)
(7) Draw out the camshaft.
(1) Check for flaws and excessive wear on the fuel, suction and exhaust cams and bearings.
(2) Measure the dimensions of camshaft bearing parts and bearings, and check the clearance between
each bearing and the shaft.
(3) To replace a camshaft bearing by press fitting it, a jig (jack) is necessary.
When incorporating a bearing to the camshaft, put the bearing so that its joint faces upward and its oil
hole is mated with oil hole of camshaft, and press fit the bearing.
Drawing 7-40. Camshaft Coupling Part
Drilled Hole Notch
(Camshaft)
7-40
3) Reassembly
Reassemble the camshaft in the sequence reverse to that of disassembly, paying attention to the follow-
ing points:
(1) Make the camshaft coupling surfaces free from adherent foreign matters and lubricating oil. Then,
align the notch with the drilled hole to reassemble the camshaft.
(2) Tighten U-nuts of the coupling part only after applying the seizure inhibitor (Three-Bond 1910 or its
equivalent) to their threaded part and bearing surface.
Drawing 7-41. Camshaft Bearing Press-fitting Procedures
7-5-3. Suc./Exh. Swing Arm
The valve mechanism forcedly lubricates the roller pins by the swing arm system.
1) Disassembly
Remove the rocker arm shaft pedestal and push rods, and disassemble the swing arm assembly accord-
ing to the following procedures:
(1) Remove the cover of cam case. Loosen the swing arm shaft clamping bolts, and remove the arm shaft
and arm together as a set.
(2) Remove the circlips form the arm shaft with use of circlip pliers (P/#28190-000020), and then remove
the swing arms and spacers.
Drawing 7-42. Swing Arm Disassembling Procedures
Oil Hole Joint
Jig
Spacer Exh. Suc.
Push Rod
Swing Arm Shaft
Swing Arm
Circlip
Push
Rod
Bracket
Roller
L
R
R
(Suc./Exh. Swing Arm)
2003.7.11R
7-41
(1) Check if the roller rotates unsmoothly (is catching) and for flaws on the outer periphery and one-sided
contact of roller.(If any defect is detected, replace the swing arm with the new one by assembly.)
(2) Check for jolting of a push rod. Measure the dimensions of the arm shaft and arm shaft bearing, and if
a measurement exceeds the usage limit value, replace the shaft or the arm.
3) Reassembly
Reassemble the suc./exh. swing arm assembly in the sequence reverse to disassembly.
(1) Check for deformation or missing of collar of swing arm shaft clamping bolt holes.
(2) Incorporate the swing arm shaft so that its set mark "R" is positioned on the right side.
Screw the clamping bolts with the set mark "R" on the right side and with the set marl "L" on the left
side.
Do not make a mistake in this incorporation. If not incorporated properly, the lubricating oil passage is
shut, resulting in burnout of the arm shaft and roller pins.
(3) After having incorporated the rocker arm shaft pedestal, adjust the suc./exh. valve head clearance.
For the adjustment procedures, refer to the following:
Chapter 6, 6-3-6. Adjustment of Suc./Exh. Valve head clearance
7-6. Fuel Injection Pump & Pump Driver
7-6-1. Fuel Injection Pump
Pay full attention to handling of the fuel injection pump in its disassembly & reassembly since it has been
made precisely and even minute foreign matters and hit mark may cause it to be burnt out or its malfun-
cion.
1) Disassembly
Socket wrench for pump
mounting
On the flywheel side 146673-92550
On the anti-flywheel side 146673-92570
Hexagonal wrench key (8 mm) 28150-080000
Hexagonal wrench key (6 mm) 28150-060000
(Fuel Injection Pump&Pump Driver)
7-42
Drawing 7-43. Fuel Injection Pump Removing Procedures
(2) Next, remove the fuel injection pump in the following sequence:
Remove the fuel injection pipe joint, overflow oil pipe, fuel oil inlet pipe, fuel oil outlet pipe, and pinion
lub. oil pipe (H.F.O. specification only).
(3) Using the exclusive socket wrenched, loosen the fuel injection pump tightening nuts to remove the pump.
(4) Disassemble the fuel injection pump, paying attention to following points:
Be sure to handle the plunger and barrel as a pair.
When removing the pressure equalizing valve body , take care not to lose any parts of
pressure equalizing valve .
Drawing 7-44. Fuel Injection Pump Disassembling Procedures
Disassemble the fuel injection pump in the ascending sequence of numbers shown in Drawing 7-44.
Invert the pump, and remove the circlip with use of the pertinent exclusive tool. Then, remove the
parts thru .
When taking off the circlip from the groove, wrap it with cloth or the like to prevent the circlip from
springing off to inflict you an injury.
Circlip
: O-ring
26206-120952
26206-120454
146673-92900
26706-120002
2008.3.13R
7-43
2) Checking & servicing of fuel injection pump
Wash each part cleanly, and take care not to allow it to be rusted.
(1) Check if the spring of pressure equalizing valve is not broken.
(2) Check if the mating surfaces of pressure equalizing valve body and barrel are free from blow-by
of fuel.
(3) Check for flaws or sludge stuck on the outer periphery of plunger .
(4) Clean the oil hole of barrel and pinion lub. oil hole of the pump body.
(5) If the tip part of deflector is dented by corrosion, replace it.
(6) Replace each O-ring with the new one.
3) Reassembly
Reassemble the fuel injection pump in the sequence reverse to disassembly, paying attention to the fol-
lowing points:
Drawing 7-45. Pressure Equalizing Valve Parts Incorporating Sequence
(1) After having incorporated each O-ring, make sure it is not warped.
(2) Apply the lubricating oil to the barrel, and incorporate it to the body.
(3) Incorporate the parts of pressure equalizing valve in the ascending sequence of numbers shown in
Drawing 7-45.
(4) Tighten the barrel clamping bolt and pressure equalizing valve body clamping bolt evenly in three
steps to the specified torque.
(5) Align the set marks of rack , pinion and plunger .
Drawing 7-46. Set Marks of Racks, Pinion & Plunger
(6) When incorporating the circlip , push in the plunger guide while checking the move of rack not
to allow the pinion to be damaged by the collar of plunger .
(7) Align the opening of circlip with the notch of the body.
Drawing 7-47. Circlip Incorporating Procedures
(8) After reassembling the fuel injection pump, makes sure the rack moves smoothly.
Chamfered
Rack (red mark on the bottom land)
Pinion (notch on tooth crest)
Pinion (notch groove)
Plunger (punch marked)
Body Notch
Circlip
7-44
7-6-2. Fuel Injection Pump Driver
The fuel injection pump driver adopts the tappet roller system that forcedly lubricates the roller pin.
Besides, on the body of the pump, the oil hole for lubricating the outer periphery of the roller is provided.
1) Disassembly
Remove the fuel injection pump and then the positioning bolt, After that, remove the driver form the cylin-
der, and disassemble it in the ascending sequence of numbers shown in Drawing 7-48.
Drawing 7-48. Pump Driver Disassembling Sequence
(1) Check for one-sided contact and flaws on the outer periphery of roller.
(2) Check if the roller rotates smoothly.
(3) Blow the air into the oil hole in the body to check for clogging.
(4) Replace the O-rings shown in Drawing 7-48. with new ones.
3) Reassembly
Reassemble the fuel injection pump driver, paying attention to the following points:
(1) Align the set mark "O" on the body with that on the tappet .
(2) Incorporate the oil shield cover with its notch part facing the operating side.
(3) Fully screw in injection timing adjusting bolt , and incorporate it in position.
(4) After mounting the fuel injection pump, adjust the injection timing to the specified timing.
For the injection timing adjusting procedures, refer to the following:
Chapter 6, 6-3-4. Adjustment of Fuel Injection Timing (p.6-12)
Fuel Injection Pump
Positioning Bolt
Guide Ring
Driver Body
Set Mark "O"
O-ring
O-ring
2002.12.25R
7-45
7-7. Governor & Governor Gear
7-7-1. Governor
The engines can be equipped with one of the three types of hydraulic governors depending on their speci-
fications. For each governor, refer to its operation manual provided separately.
Before removing the governor, record the speed regulation and status of each adjusting point.
When removing the governor, do not give an impact to the gear shaft, terminal shaft, speed control
shaft, etc.
7-7-2. Governor Gear
The governor gear is drive via the bevel gear on the camshaft gear side. The governor is driven by the gov-
ernor gear via a spline coupling.
Drawing 7-49A. Type NZ (or RHD) Governor Driver
1) Disassembly
When removing the governor, take it out vertically, paying attention not to flaw the driving shaft spline.
[ In the case of an engine equipped with Type RHD governor ]
(1) Disassemble the governor gear in the ascending sequence of numbers shown in Drawing 7-49A.
(1) Check the contact of bevel gear tooth surface.
(2) Check the contact and stepped wear of driving shaft spline.
Either of two types of governor gears is applicable to the governor used.
Loosen the gear tightening nut , and remove the parts thru to the gear side.
Remove the circlip with use of circlip pliers. Remove the spline coupling to the governor side.
(The bearings & are press-fitted to the driving shaft .)
Fit the driving shaft spline with the governor spline, and check if jolting is not excessive.
Spline Coupling
Governor Mount
(Governor & Governor Gear)
7-46
(3) Replace the ball bearings every 8,000 to 10,000 hours even if their appearance is free from abnormality.
When incorporating the ball bearings & to the driving shaft, press fit them, applying the load to
the inner race of the bearings.
3) Reassembly
Reassemble the governor gear in the sequence reverse to disassembly.
(1) Mount the governor gear, and check the backlash of the bevel gear.
When mounting the governor, let its spline fit with the governor gear spline under the governor own
weight.
[ In the case of an engine equipped with Type SG governor ]
Governor driving gear
Item of importance for disassembly & reassembly
(1) Replace the ball bearing of governor driving gear with the new one by 6,000 8,000 hours of opera-
tion (about two years) or when they are resulted in abnormal wear.
(2) At the time of attaching the driving gear, confirm the backlash of bevel gear, and adjust the backlash
by regulating the number of shims of bevel gear boss part.
(3) At the time of attaching the governor, check to see that there is no forcing to fitting of governor shaft
and spline coupling.
(4) The backlash of spur gears (A) and (B) should be 0.1 0.15mm. (Approximately 98 118N-m (10
12kgf/m) is suggested for spur gear (A) tightening torque.)
(5) Pay attention to the direction of oil seal. (The correct direction is that the oil seal faces downward.)
Drawing 7-49B. Type SG Governor Driver
To adjust the backlash, remove the bevel gear from the driving shaft, and adjust the thickness of
adjusting shim .
Spur Gear (A)
Spur Gear (B)
Bevel Gear
Governor
(Type SG)
Spline Joint
Ball Bearing
Oil Seal
Adjusting Shim
2002.12.25R
7-47
7-7-3. Coupling Adjustment of Governor
Improper coupling of the governor and fuel injection pump may adversely affect the performances of gov-
ernor, disable the engine from stopping and cause the rotational speed to rise excessively. After having
serviced or replaced the fuel injection pump and/or governor, adjust this coupling according to the following
sequence.
(1) Check if the clearance between the coupling rod and the connecting pin on both ends od coupling rod
is not excessive.
(2) Set the start/stop lever in the STOP position.
(3) Make the rack scales of fuel injection pumps of all cylinders set to the same position within the range
of graduation 9 to 10.
(At this time, also make sure the first lever moves smoothly.)
Drawing 7-50. Fuel Injection Pump Rack Adjusting Procedures
1) If the Type NZ (or RHD) governor is equipped
Drawing 7-51. Type NZ (or RHD) Governor Connecting Procedures
Injection Volume
Rack Scale
adjusting screw
Lock nut
1st Lever
Rack
Decrease Increase
95 mm
Fuel
Increase Decrease
Governor
Output Shaft
Pointer
Lock Bolt
Governor Lever
Coupling Rod
Start/Stop Lever
Coupling Bolt
2nd Lever
1st Lever Shaft
2003.4.17R
7-48
(Lub. Oil Pump & Lub. Oil Press. Reglat. Valve)
(4) Adjust the screwing-in of the 2nd lever coupling bolt so that the distance between the center of the 1st
lever shaft and the center of the coupling rod becomes about 95mm.
(5) Connect the coupling rod to the 2nd lever coupling bolt.
(6) Insert a blade screwdriver into the governor output shaft end, fully turn the shaft in the fuel
DECREASE direction so as to set the pointer at the FUEL "0" indication.
(7) Incorporate the governor lever to the governor output shaft. (Loosen the governor lever lock bolt in
advance.)
(8) Connect the coupling rod to the governor lever. (The governor lever has four holes. Connect the cou-
pling rod with the same hole as connected before disassembly.)
(9) Insert a blade screwdriver into the governor output shaft end, set the pointer to the FUEL "1" indica-
tion, and tighten the governor lever lock bolt.
Check that both ends of coupling rod are not twisted.
Alternately setting the star/stop lever in the START and STOP positions, and make sure each rack
scale is set at the graduation 13 (non-injection position) of a less (within the range of graduation 9
to 10) while the lever is set in the STOP position.
7-8. Lub. Oil Pump, Lub. Oil Pressure Regulating Valve & Lub. Oil Cooler
7-8-1. Lub. Oil Pump
The lubricating oil pump is a gear pump of which body is built in incorporates with a pressure regulating
valve and a safety valve. The pump gear and shaft are shrink fitted.
1) Disassembly
(1) Disconnect the suction pipe, delivery pipe and pressure regulating valve pilot pipe from the lub. oil
pump, and then remove the pump.
(2) Disassembly of lubricating oil pump
remove the pump drive gear, and disassemble the pump.
Detach the side cover from the pump. Fit the (M12 1.75) bolt at the part of the driving gear to
lock it. Then, loosen (or tighten) the tightening nut.
Drawing 7-52. Lub. Oil Pump Removing/Disasembling Procedures
The pump is positioned with knock pins. Remove the pump by fitting the pump mounting bolts to the
respective disassembling threaded holes and jacking up the pump.
Outlet
Pilot Pipe Knock Pin
Drive Gear
Tightening Nut
Side Cover
Knock Pin
Pressure Adjusting Bolt
Inlet
7-49
(Lub. Oil Pump & Lub. Oil Press. Reglat. Valve)
(3) Disassembly of the lub. oil pressure regulating valve & safety valve
Be careful of a spring which springs out from the safety valve and/of pressure regulating valve in dis-
assembly to inflict you an injury.
Disassemble the pressure regulating valve after loosening the pressure adjusting bolt.
Drawing 7-53. Pressure Regulating Valve & Safety Valve
[ Pump body & pump gear ]
(1) Check for flaws and seizure on the tooth surface and side of the pump gear.
(2) Check for flaws and seizure on the pump gear shaft and gear shaft bearing.
(3) Measure the clearance between the pump gear and the pump body at the bearing part. If the mea-
surement exceeds the allowable value, replace either part whichever is worn more than the other.
[ Pressure regulating valve & safety valve ]
(1) Check for flaws on the pilot piston, pressure regulating valve, safety valve and valve springs.
(2) Check the operation of pilot piston, pressure regulating valve and safety valve, and make sure they
operate properly.
Directing the V-groove of pressure regulating valve toward the pilot piston, incorporate the pressure
regulating valve.
3) Reassembly
Reassemble the lubricating oil pump in the sequence reverse to disassembly.
Safety Valve
Pressure Reg. Valve
O-ring
Spring Shoe
Lock Nut
Pressure
Adjusting Bolt
Spring
Spindle
V-groove
Pilot Piston
7-50
7-8-2. Lub. Oil Cooler
The lub. oil cooler is of the multi tubular type, and chemical cleaning seats that enable cleaning of the oil
cooler without removing it are equipped on the lubricating oil passage side.
1) Chemical cleaning procedures
The hose, pump and the like required for chemical cleaning are not included in the standard provision of
this engine.
(1) Drain the lubricating oil from the oil cooler, rearrange the respective baffle plates , & at the oil
cooler inlet and outlet.
(2) Remove the round covers from the chemical cleaning seats and connect a hose with each seat. Then,
circulate the cleaning solution.
(3) After having finished cleaning, drain the cleaning solution, and return the baffle plates and round cov-
ers to their former condition.
Drawing 7-54. Chemical Cleaning Procedures
2) Disassembly
Drain the lubricating oil from the lub. oil cooler, fix the cooler body with rope, and remove it from the
engine.
(1) Remove the lub.oil strainer.
(2) Remove the caps from the cooling water inlet and outlet.
(3) Remove the lub. oil thermostatic valve.
(4) Remove the cooling water pipe assembly.
To prevent the cleaning solution from being mixed into the lubricating oil, be sure to treat the oil cooler
after chemical cleaning.
Solution inject Port

Lub. Oil Strainer
Thermostatic Valve
Bypass Pipe
Lub. Oil Cooler
(Lub. Oil Cooler)
7-51
(1) For checking and servicing of lub. oil strainer and lub. oil thermostatic valve, refer to the followings:
Lub. oil strainer: Chapter 6, 6-3-12 (p.6-27)
Thermostatic valve: Chapter 6, 6-3-8 (p.6-20)
(2) Clean the pipe on the cooling water side and lubricating oil side of cooling water pipe assembly.
(3) Replace the O-rings at the cooling water inlet and outlet side covers with new ones.
4) Reassembly
Reassemble the lub.oil cooler in the sequence reverse to disassembly, paying attention to the following
points:
(1) Align the set marks of cooling water pipe assembly and lub. oil cooler body when incorporating the
pipe assembly to the cooler body.
Drawing 7-55. Set Marks (on The Cooling Water Outlet Side)
Descale the pipe on the cooling water side with a long-handle brush.
For the pipe on the lubricating oil side, cleaning combining washing with such a sludge cleaning
agent as Neos and cleaning with steam is appropriate.
End Plate
Tube
Body
Tube
(Low-fin type)
O-ring
(Lub. Oil Cooler)
7-52
7-9. Cooling Water Pump
The cooling water pump is a centrifugal pump. The only difference between the high-temperature water
side and the low temperature water side is the direction of cooling water inlet and outlet. The impeller is
incorporated to the shaft by screw tightening.
Note that the thread of impeller and that of impeller tightening nut are reverse handed. When disas-
sembling/reassembling the cooling water pump, be careful of the loosening/tightening direction.
1) Disassembly
Disassemble the pump in the ascending sequence of numbers shown in Drawing 7-56. Remove the
impeller with use of the specified exclusive tool (P/#146673-92750).
Drawing 7-56. Cooling Water Pump
Remove the ball bearings & that are press-fitted to the shaft together with the shaft.
(1) Measure the clearance between the impeller and casing. If the measurement exceeds the allow-
able value, replace either part whichever is worn more than the other.
(2) If necessary, replace the mechanical seal and oil seal .
3) Reassembly
Reassemble the cooling water pump in the sequence reverse to disassembly, paying attention to the fol-
lowing points:
(1) When incorporating the shaft, be careful not to flaw the lip of oil seal.
(2) Tighten the impeller and impeller tightening nut to the specified torque.
Do not make a mistake in the incorporating direction.
When press-fitting a bearing to the shaft, apply the load on the inner race of the bearing.
Casing
Impeller Attaching/Detaching Procedure
Exclusive Tool
Incorporation Disassembly
Oil Seal Incorporating
Direction
A
(Cooling Water Pump)
7-53
7-10. Fuel Oil Feed Pump
The fuel oil feed pump is a gear pump. The pump gear on the driving shaft side are coupled to the shaft
through a spline.
1) Disassembly
Disassemble the pump in the ascending sequence of numbers shown in Drawing 7-57.
(1) Remove the ball bearings & that are press-fitted to the driving shaft together with the shaft.
(2) When replacing the oil seal, detach the circlip , and draw out the seal toward the driving gear
side.
Drawing 7-57. Fuel Oil Feed Pump
(1) Check the contact of the spline fitting part of driving shaft and pump gear . If the clearance (play)
is too large, replace either part whichever is worn more than the other.
(2) Check the parts of driving shaft that make contact with its oil seals & . Then, if the wear is sub-
stantial, replace the shaft.
(3) If necessary, replace the oil seals.
(5) The bypass valve functions also as a safety valve of fuel oil feed pump. During operation, keep the
bypass valve closed.
Remove the plug and check the operation of piston.
If the fuel leaks from the handle shaft part, replace the O-ring.
Drawing 7-58. Bypass Valve
The oil seals & are different parts. Do not make a mistake in their incorporating position and
direction.
When press-fitting the ball bearing to the shaft, apply the load on the inner race of the bearing.

Oil Seal Incorporating
Direction
Pump Body
Spline
Adjusting Screw
Handle Shaft
Lock Nut Valve Holder Piston O-ring
(Fuel Oil Feed Pump)
7-54
3) Reassembly
reassemble the fuel oil feed pump in the sequence reverse to disassembly, pay attention to the following
points:
(1) When incorporating the shaft, be careful not to flaw the lip of oil lip seals.
(2) Apply a thin and uniform film of liquid packing (Three-Bond TB 1201 or its equivalent) on the mating
surfaces of pump cover and pump body.
(The thickness of the packing after clamping must be 0.02mm or less.)
(3) Align the hole of spacer for oil seal with the over flow oil take-off hole of the body.
(4) Replace the bend washer with the new one every time the fuel oil feed pump is disassembled.
7-11. Suction/Exhaust System
7-11-1. Boost Air Cooler
The boost air cooler is a plate finned box structure. It incorporates a duct integrated with the boost air inlet
and outlet pipe, and its connection parts are equipped with V-ring packing.
Drawing 7-59. Boost Air Cooler
Drawing 7-60. Boost Air Inlet Side V-ring Removing Procedures
When servicing the boost air cooler, detach the V-ring on the boost air inlet side, and then remove the
cooler together with the duct.
Cooling Water Inlet/Outlet Cover
V-ring (Inlet)
Drain Cock
Water Return Cover
Duct
Boost Air Cooler
Packing Housing
V-ring
Detaching/Attaching Plate
(Suc. & Exh. System/Air Cooler)
7-55
(Suc. & Exh. System/Air Cooler)
1) Disassembly
Disassemble the boost air cooler, removing its parts according to the following sequence:
(2) Remove the boost air cooler thermal insulating plate, thermometer, cooling water pipe and so forth.
(3) Remove the V-ring on the boost air inlet side.
(4) Fit an eyebolt on the top of duct, hold the duct with rope, and remove it toward the non-operating side.
(5) Remove the duct according to the following procedures:
Carefully disassemble the boost air cooler so as not to flaw the V-ring incorporated part, otherwise
this causes a boost air leak.
Invert the boost air cooler so that the cooling water inlet and outlet caps face upward.
Unscrew the duct mounting bolts, fit an eyebolt to the cooler, life the cooler, and then remove the duct
from the cooler.
(1) Clean the air side (plate fin) with steam or soak it in the cleaning fluid, blow the compressed air
against it, and finally wash it in water.
(2) Remove the water return cover on the cooling water side. Then, clean the cooler interior, brushing
with a long-handle brush.
(3) Check the coating on the inner surface of the duct and inner surface of the cooler side plate. If the
coating has peeled off, repair it with the following paint.
(4) Check for clogging of a drain hole.
(5) Replace the packings with new ones.
3) Reassembly
Reassemble the boost air cooler in the sequence reverse to disassembly, paying attention to the follow-
ing points.
(1) Fit the V-ring on the boost air outlet side to the cylinder block. After mounting the boost air cooler,
incorporate the V-ring on the boost air inlet side.
Packing (V-ring) detaching/attaching tool 146673-92800
Eyebolt (M12) 26610-120002
Loosen the packing housing mounting bolts, put the detaching/attaching plate into both sides of the
housing to hold the packing, and then remove the packing together with the housing.
The appropriate cleaning fluid is the following products or their equivalents.
Neos Co.,Ltd: Neos One-1
Kurita Water Industries Ltd.: Emocon 1E55
Inner surface of duct (heat-resistant silicone paint)
Oshima Kogyo: Pirojin IN Color G2 or its equivalent
Inner surface of cooler side plate (silicone epoxy pain)
Oshima Kogyo: Silicone Epoxy ING #2
7-56
7-11-2. Exhaust Manifold
1) Disassembly
Lifting the exhaust manifold cover with use of a lifting use of a lifting eyebolt (P/#26610-100002) and
a chain block or the like, remove the cover.
Disassemble the exhaust manifold while checking whether the steady rest and the clamping bolts are not
loose.
Drawing 7-61. Exhaust Manifold & Expansion Joint
Be careful not to confuse stainless steel bolts and nuts of exhaust manifold, expansion joint and
steady rest with those made of other material for clamping these parts.
2) Reassembly
(1) Apply the seizure inhibitor to each bolt or nut, and then tighten it.
(2) Checking the mark stamped on the flange of the expansion joint, fit it in the proper incorporating direc-
tion according to the mark.
Drawing 7-62. Exhaust Expansion Joint
7-11-3. Turbocharger
For disassembling and servicing of the turbocharger, refer to the operation manual separately provided for
it.
If the expansion joint is fitted in the reverse direction, carbon is entrapped in the clearance, causing the
expansion joint to be broken in a shorter period.
The turbocharger mount is provided with the boost air and lubricating oil passages. After having
removed the turbocharger, cover the ports of boost air and lubricating oil passages to prevent foreign
matters from entering the turbocharger.
Stay Rest
Exhaust Manifold Expansion Joint
Eye Bolt
Gas Flow
Expansion Joint Mark
(Suc. & Exh. System/Turbocharger)
2005.1.21R
7-57
(Air Motor)
7-12. Air Motor
Refer to the attached Service Manual for Engine Air Starters (Model 45M).
Restrict disassembly and repairs of the air motor to disassembly, checking and the following parts replace-
ment of the air inlet housing and the spool valve.
O-rings of the spool valve and the air inlet housing
Starting solenoid valve
Control module
Pilot air hose
1) Disassembly (of the spool valve)
After removing the air motor, disassemble it in the ascending sequence of numbers given in Drawing 7-64.
When unscrewing a bolt used to fasten the nozzle valve seat to the inlet housing, be careful so
that the spool valve does not spring out.
Drawing 7-63. Spool Valve Disassembling Procedures
2) Maintenance checking
(1) Check the sliding surface and the seat face of the spool valve if they are not flawed not the foreign
matter has not been bittern in.
(2) Check the nozzle/valve seat if the seat face and nozzle part are not damaged.
(3) Replace the O-rings with the new ones.
3) Reassembly
Reassemble the air motor in the sequence reverse to disassembly, paying attention to the following
points:
(1) Apply grease to the sliding surface of the spool valve.
(2) Use sealing tape at the threaded part of the elbow of pilot air hose to that the air does not leak from
this part.
(3) Tighten each bolt with the following torques:
5 bolts for nozzle/valve seat: 7.2 N-m (0.7 kgf-m)
4 bolts for air inlet housing: 19.2 N-m (2 kgf-m)
4 bolts for air inlet pipe: 94.9 N-m (9.7 kgf-m)
3 bolts for air motor: 136 N-m (13.9 kgf-m)
Spool Valve Air Inlet Housing
Pilot Air Hose
Standing Solenoid Valve Control Module
O-ring
O-ring
7-58
7-13. Electromagnetic Pickup
1) Adjustment on the mounting dimensions
When the pickup is replaced or removed, be sure to adjust the clearance.
If the adjustment on the clearance is found poor, the rotational speed may not be detected, and the
(overspeed) protective device may not actuate.
Adjust the screwing-in of the pickup so that the clearance between the pickup tip and the outer periph-
ery of the ring gear becomes 1.4 to 2.1 mm.
(Screw in the pickup so that its tip contacts the outer periphery of the flywheel ring gear, and then
loosen by 1 to 1.5 turn.)
Tighten the lock nut securely.
Drawing 7-64. Electromagnetic Pickup Mounting Procedures
This pickup is a sensor to detect the rotational speed of the engine and is mounted near the outer
periphery of the flywheel ring gear.
1.42.1 mm
(Junction Box)
Electromagnetic Pickup
Lock Nut
Flywheel Ring gear
(Electromagnetic Pickup)
7-59
7-14. Stopping Air Piston
Do not disassemble adjustment nut and adjust bolt in the case where parts replacement is not
needed.
The stroke of the piston has been properly adjusted prior to shipment from out factory, do not readjust it.
When parts replacement is needed, do so with attention paid to the following:
Measure the dimension L1, L2 when disassembly is needed, and set it in the same dimension as the
measured L1, L2 when reassembling this air piston.
1) Disassembly
Disassemble the air piston in the ascending sequence of numbers given in Drawing 7-65.
Drawing 7-65. Stopping Air Piston
2) Reassembly
Reassemble the air piston in the sequence reverse to disassembly.
Incorporate the piston, applying lubricating oil or lithium series grease to its sliding part.
Replace the O-ring with the new one.
This piston purports to stop the engine when the protective device actuates and in case of remote
stopping, and to control fuel injection volume when engine is started up.
, : stopping (to stop supply of fuel oil) air piston.
: fuel injection volume controling air piston.
Conduct such a performance test once in every three months.
Send the control air into the each air pistons, and confirm the movement of the sopping air piston
adjust nut
A
A C
B
B
L
2
L
2
L
1
L
1
Adjust Nut
Adjust Nut
Eng. Control Stop Control Air
Control Air
Eng. Safety Stop
Safety System
Eng. Start
Adjust Bolt
Adjust Bolt
Eng. Start
Eng. Stop
(Stopping Air Piston)
7-60
MEMO
8.PRINCIPAL DIMENSIONS & PART MASS FOR DISASSEMBLY & SERVICING
8-1
8. PRINCIPAL DIMENSIONS & PART MASS FOR DISASSEMBLY & SERVICING
Drawing 8-1. Principal Dimensions for Disassembly & Servicing
[Unit: mm]
Cooling Water Outlet
Collecting Pipe
Exh. Manifold
Center of Camshaft
Center of Crankshaft
Center of Turning Gear
Turning Bar
Center of Cylinder
1
1
5
0
1
1
1
5
425
225
879
1
3
7
0
4
0
0
15
30
495
965
1
3
2
Dismantling to the Frontal End
Piston Cyl. Liner Cyll. Head
Boost Air
Cooler
1057
1
6
6
6
1
7
1
0
1
4
7
1
Dismantling to the Operating Side
Dismantling to the Rear End
Camshaft Split in Two
Cooling Water Pump
Fuel Feed Pump
When Drawing-out en bloc:1988
Center of No.6 Cyl.
Turbocharger
2
0
8
8
2
0
5
5
1
7
3
0
1
6
2
2
1
8
9
6
678
707
1178
Dismantling to the Rear End Dismantling to the Frontal End
8.PRINCIPAL DIMENSIONS & PART MASS FOR DISASSEMBLY & SERVICING
8-2
8-1. Principal Part Mass for Disassembly & Servicing
(1) When hoisting a part, use rope and lifting gear and hook that can withstand the can withstand the
weight of the part.
(2) When disassembling any of the parts prefixed with an asterisk (*) in the following table, use the
attached exclusive tool.
[Unit: kg]
Part Description 6N18L 6N18AL Remarks
* Cylinder head 105
* Piston & connecting rod assy. 42
* Cylinder liner 40
* Air cooler 300 Incl. the casing
Lub. oil cooler 162 Incl. the strainer & thermostatic valve
Turbocharger
RH133 63
RH143 145
Fuel feed pump 16
Lub. oil pump 30
Cooling water pump 35
Air motor 18
Camshaft (split in two) 41 2
Camshaft driving gear 15
Intermediate gear assy. 20
* Exhaust manifold cover 45
* Main bearing cap 22
Anti-flywheel end gear case 62
Oil pan 200
Cylinder block 1,496
Crankshaft 760 846 Incl. the balance weight
Flywheel 870 650 Incl. ring gear
2004.3.29R
9.TABLE OF TIGHTENING TORQUES OF MAJOR BOLTS
9-1
2002.7.22R
9. TABLE OF TIGHTENING TORQUES OF MAJOR BOLTS
Tighten the major bolts by the specified procedures.
If tightened improperly, a personal injury or damage of device may be caused. Be cautious.
(1) Unless otherwise specified,apply lub.oil on the thread and bearing surface, and then tightening a
bolt or nut.
(2) On the parts prefixed with a star ( ) in the following tables, a match mark is stamped. However,
when tightening any of these parts, do not refer to the macth mark but tighten it to the specified
torque, specified tightening angle or specified hydraulic pressure.
9-1. Hydraulic Peressure Clamping Bolt
9-2. Angle Clamping Bolts
(1) Before tightening a connecting rod bolt, apply the Protec grease on its bearing surface and lub.oil
on its thread.
(2) Tighten a bolt to the seating tightening torque, then tighten it to the specified angle.
Part Description
Screw
Dia
Pitch
Face-to-Face
Width of
Bolt/Nut
(mm)
Specific Hydraulic
Pressure
MPa (kgf/cm
2
)
Remarks
Cylinder head tightening nut M332.0 Round 58.8 0.5(600 5)
Main bearing cap tightening nut M332.0 Round 58.8 0.5(600 5)
Part Description
Screw Dia.
Pitch
Face-to-Face
Width of
Bolt/Nut
(mm)
Seating
Tightening
Torque
N-m (kgf-m)
Specified
Tightening
Angle
(deg.)
Remarks
Connection rod bolt M25 1.5 32 49(5) 120
+3
-0
Balance weight clamping bolt M24 2.0 32 49(5) 80
+3
-0
(Volume:4pages)
9-2
2009.6.18R
9-3. Other Major Bolts (Torque Tightening)
(1) Before tightening a flywheel clamping bot or fuel injection valve nozzle sleeve, apply Protec gease
on its thread and bearing surface.
(2) Before tightening a camshaft coupling nut, apply seizure inhibitor (Three-Bond 1910 or its equiva-
lent) on its thread and bearing surface.
(3) The parts prefixed with an asterisk (*) in the following table are provided with an exclusive tool,
respectivery.
(4) Be sure to tighten a part with a torque wrench to the specified torque.
Part Description
Screw Dia.
Pitch
Face-to-Face
Width of
Bolt/Nut (mm)
Tightening Torque
Remarks
N-m (kgf-m)
Indicator cock tightening nut M121.75 19 59 69 6 7
Rocker arm shaft stand clamping bolt M16 1.5 24 186206 19 21
* Fuel injection valve nozzle sleeve
M22 1.5
2 grooves
157167 16 17 Engine Using MDO
M30 1.5 245265 25 26 Engine Using HFO
Fuel injection valve guard tightening
nut
M10 1.5 17 39 44 4 4.5
* Fuel injection valve case nut M28 1.5 27 167176 17 18
* Fuel injection valve injection pressure
regulating lock nut
M33 1.5 41 47 51 4.8 5.2
* Fuel injection pipe joint bolt (on cyl.
head side)
M8 1.25
6
(hex. socket)
20 2
* Fuel injection pipe joint bolt (on pump
side)
M10 1.5
8
(hex. socket)
69 7
* Fuel injection pump tightening nut M121.75 19 74 83 7.5 8.5
Fuel injection pump equalizing valve
body clamping bolt
M10 1.5
8
(hex. socket)
54 59 5.5 6.0
Fuel injection pump barrel retaining
bolt
M10 1.5
8
(hex. socket)
54 59 5.5 6.0
Fuel injection pump protector M20 1.5 27 49 59 5.0 6.0
Fuel injection timing adjust bolt lock
nut
M22 1.5 30 196245 20 25
Camshaft coupling nut M121.25 17 88 98 9 10 U-nut
Cam gear clamping bolt M14 1.5 19 137157 14 16
Tightening together
with tachometer driv-
ing disk
Idle gear shaft clamping bolt M16 1.5 24 118 127 12 14
Idle gear retainer clamping bolt M121.75 19 59 69 6 7
Cooling water pump impeller tightening
nut
M16 1.5 24 93 103 9.510.5 Left hand screw
* Cooling water pump impeller M22 2.5
round socket
4 points
206225 21 23 Left hand screw
Cooling water pump driving gear tight-
ening nut
M24 2.0 36 235255 24 26
Cooling water pump idle gear shaft
clamping bolt
M16 1.5 24 118 137 12 14
Main bearing cap side bolt M22 1.5 32 343382 35 39
Flywheel clamping bolt M20 1.5 24 510569 52 58
Exhaust manifold clamping bolt M121.75 19 59 69 6 7
Exhaust expansion joint clamping bolt M121.75 19 59 69 6 7
Lub.oil pump driving gear tightening nut M24 2.0 36 157177 16 18
Swing arm shaft clamping bolt M16 1.5 24 118 137 12 14
9-3
9-4. General Bolts
(1) Tighten any bolts other than the major ones according to the following table.
(2) Tighten a part whose clamping section is made of aluminum, tighten it to 80% of the torque shown
in the following table.
(3) The following table is applicable only to the bolts whose Part No. (an 11-digit numeral) shown in the
attached Parts List consists of 2 at its first place and 2, 5 or 6 at its fifth place.
Screw Dia.
Pitch (mm)
Face-to-Face
Width of Bolt/Nut
(mm)
Tightening Torque
N-m (kgf-m)
M6 1.0 10 10 12 (1.0 1.2)
M8 1.25 13 24 27 (2.4 2.8)
M10 1.5 17 44 54 (4.5 5.5)
M12 1.75 19 78 98 (8 10)
M14 1.5 22 123 152 (12.5 15.5)
M16 1.5 24 206 245 (21 25)
M16 2.0 24 206 245 (21 25)
2002.7.22R
9-4
MEMO
10.CLEARANCES & WEAR LIMITS OF MAJOR PARTS
10-1
10. CLEARANCES & WEAR LIMITS OF MAJOR PARTS
: The 1st ring is to be replaced with the new one when its plated layer is worn out and base metal begins to be
exposed; the 2nd ring, when the taper face is gone.
(Unit in mm)
Item Sketch
Dimension Std
Clearance
Assembling
Time
Max.
Allowance
Clearance
Usage
Limit of
Parts
Normal Tolerance
C
y
l
i
n
d
e
r

&

c
y
l
i
n
d
e
r

l
i
n
e
r
Inner dia. of cylinder upper
part
246
+0.029
0
A1=0.075
0.139
A1=0.25
+0.1
Outer dia. of cylinder liner
upper part
-0.075
0.110
-0.2
Inner dia. of cylinder lower
part
222
+0.029
0
A2=0.020
0.094
A2=0.2
+0.13
lower part
-0.020
0.065
-0.13
Inner dia. of cylinder lower
part
218
+0.029
0
B=0.015
0.088
B=0.2
+0.13
lower part
-0.015
0.059
-0.13
Top clearance 2.0 0.20
C=1.8
2.2
C=2.5

Inner dia. of protection ring 178 0.05
D=0.905
1.045

+0.8
Outer dia. of piston head 177.025 0.02
Inner dia. of cylinder liner 180
+0.030
0
E=0.093
0.153
E=0.3
+0.4
deflection
wear of
0.2
Outer dia. of piston skirt part 179.892 0.015 -0.2
P
i
s
t
o
n

p
i
s
t
o
n

p
i
n

&

r
i
n
g
s
Radial thick. of piston
rings, No.1 No.2
F=6.5 0.15
Radial thick. of oil ring F=5.0 0.25
4.7
Width of piston ring, No.1
4.5
-0.065
-0.085
No.1
G=0.110
0.155
No.1
G=0.4
-0.2
Width of piston ring groove,
No.1
+0.070
+0.045
+0.3
Width of piston ring, No.2
4.0
-0.010
-0.030
No.2
G=0.055
0.100
No.2
G=0.4
-0.2
Width of piston ring groove,
No.2
+0.070
+0.045
+0.3
Width of oil ring
6.0
-0.010
-0.030
H=0.030
0.065
H=0.4
-0.2
Width of oil ring groove
+0.035
+0.020
+0.3
Inner dia. of piston pin metal
75
+0.100
+0.080
J=0.080
0.113
J=0.25
+0.17
Outer dia. of piston pin
0
-0.013
-0.05
Inner dia. of piston pin hole
+0.045
+0.030
K=0.030
0.058
K=0.15
+0.15
Outer dia. of piston pin
0
-0.013
-0.15
10-2
(Unit in mm)
Item Sketch
Dimension Std
Clearance
Assembling
Time
Max.
Allowance
Clearance
Usage Limit
of Parts
Normal Tolerance
C
r
a
n
k
s
h
a
f
t
Inner dia. of crank pin bear-
ing
145
+0.152
0.080
L=0.080
0.170
L=0.25
+0.20
Outer dia. of crank pin
0
-0.025
deflection
wear of
0.1
Inner dia. of main bearing
180
+0.189
+0.120
M=0.120
0.214
M=0.25
+0.20
Outer dia. of journal
0
-0.025
deflection
wear of
0.1
Width of datum part main
bearing
80
-0.140
-0.200
N=0.140
0.230
N=0.5
-0.4
Width of datum part journal
+0.035
0
+0.35
Deflection
Refer to
Chapter 6 Maintenance Checking
6-3-17 Measurement of crankshaft
deflection, 3) Allowable value of the
deflection.
V
a
l
v
e

M
e
c
h
a
n
i
s
m
Valve head clearance
(suc./exh.)

Refer to Chapter 3 TABLE OF ENGINE
STANDARD ADJUSTMENTS.
Outer dia. of suction valve
14
-0.060
-0.080 R1=0.060
0.104
R1=0.32
-0.32
Inner dia. of suction valve
guide
+0.024
0
+0.26
Outer dia.
of exhaust
valve
Chrome-plated
14
-0.058
-0.078
Chrome-plated
R2=0.058
0.102
Nimonic
R3=0.068
0.112
R2=0.32
R3=0.35
-0.32
Nimonic
-0.068
-0.088
-0.35
Inner dia. of exhaust valve
guide
+0.024
0
+0.28
Inner dia. of valve bridge
16
+0.080
+0.060
S=0.014
0.052
S=0.2
+0.18
Outer dia. of valve bridge
guide
+0.046
+0.028
-0.18
Margin thickness of suc./
exh. valve poppet part
T=4.7 0.1
4.3
Width of suc./exh. valve
seat
U= 0.2
5.4
Dia. of suc./exh. valve seat
contact part
V=57 0.1 58
Outer dia. of rocker arm
shaft
36
-0.009
-0.034
W=0.029
0.119
W=0.25
-0.1
Inner dia. of rocker arm
bush
+0.085
+0.020
+0.22
Inner dia. of swing arm
40
+0.03
+0.01 X=0.010
0.069
X=0.2
+0.2
Outer dia. of swing arm
shaft
0
-0.039
-0.1
2006.10.16R
10-3
(Unit in mm)
Item Sketch
Dimension Std
Clearance
Assembling
Time
Max.
Allowance
Clearance
Usage
Limit of
Parts
Normal Tolerance
C
a
m
s
h
a
f
t
Outer dia. of camshaft
datum part
120
-0.072
-0.107
Y=0.072
0.197
Y=0.3
-0.17
Inner dia. of camshaft
datum part bearing
+0.090
0
+0.17
Thrust clearance of cam-
shaft datum part
6
-0.15
-0.20
Z=0.200
`0.310
Z=0.5

Width of camshaft thrust
collar housing
+0.11
+0.05

Outer dia. of camshaft
intermediate part
120
-0.072
-0.107
a=0.072
0.197
a=0.3
-0.17
Inner dia. of camshaft inter-
mediate part bearing
+0.095
0
+0.17
L
u
b
.

o
i
l

p
u
m
p
Outer dia. of lub. oil pump
shaft
30
-0.040
-0.053
b=0.040
0.074
b=0.2

Inner dia. of lub. oil pump
shaft bush
+0.021
0
+0.15
Clearance betw. pump
case & gear
72
+0.046
0
c=0.200
0.296
c=0.3

Outer dia. of gear
-0.200
-0.250

Width of pump case
6N18L
77
6N18AL
66
bell mounting
coupling spec
6N18L
72
+0.046
0
d=0.060
0.136
d=0.18
Width of pump gear

-0.060
-0.090

C
o
o
l
i
n
g

w
a
t
e
r

p
u
m
p
Outer dia. of cooling water
pump impeller boss
94
-0.13
-0.18
e1&e2
=0.78
0.87
e1&e2
=1.60
-0.6
Inner dia. of casing
+0.69
0.65
+1.0
F
u
e
l

O
i
l

F
e
e
d

P
u
m
p
Outer dia. of fuel oil feed
pump shaft
25
-0.020
-0.041
b=0.020
0.062
b=0.2
-0.1
Inner dia. of fuel oil feed
pump shaft bush
+0.021
0
+0.1
Inner dia. of pump case
48
+0.025
0
c=0.080
0.130

Outer dia. of pump gear

-0.080
-0.105

Width of pump case
12
+0.018
0
d=0.1
0.2
(Liquid
packing
0.02)
Width of pump gear

-0.016
-0.034

E
E
F
D
D
2008.4.21R
10-4
T
r
a
n
s
m
i
s
s
i
o
n

g
e
a
r
Gear backlash
(Timing gear
& pump
drive gear)
M=4.5

f=0.15
0.25
f=0.5

(Governor
gear)
M=3.0

f=0.12
0.20
f=0.3

Outer dia. of cam driving
intermediate gear shaft
70
-0.030
-0.060
g=0.030
0.090
g=0.2
-0.17
Inner dia. of the aboves
bush
+0.030
0
+0.14
Outer dia. of pump driving
intermediate gear shaft
70
-0.030
-0.060
h=0.030
0.090
g=0.2
-0.17
Inner dia. of the aboves
bush
+0.030
0
+0.14
O
i
l

s
h
i
e
l
d
,

f
l
y
w
h
e
e
l

s
i
d
e
Outer dia. of crankshaft
220
0
-0.046
j=0.030
0.446

Inner dia. of oil shield

+0.400
+0.300

(Unit in mm)
Item Sketch
Dimension Std
Clearance
Assembling
Time
Max.
Allowance
Clearance
Usage
Limit of
Parts
Normal Tolerance
2008.4.21R
11.TROUBLESHOOTING & COUNTERMEASURES
11-1
11. TROUBLESHOOTING & COUNTERMEASURES
The causes of abnormalities and troubles are diverse, and they break out from compsite factors.
Catching a change in running performance and referring to the record of maintenance and servicing
date and the history of part replacement, locate the cause early and take the proper countermea-
sures.
11-1. Starting Failure
1) Flywheel not turned.
2) Flywheel turned, but ignition not taken place.
11-2. Rotational Speed Dropped Spontaneously.
11-3. Output of Each Cylinder not in Unifomity. (Dispersion of the maximum combustion pressure
and exhaust temperature is large among cylinders.)
11-4. Bad Color of Exhaust Gas
11-5. Lub. Oil Pressure Dropped below the Specified Pressure
11-6. Unusual Sounds Heard (Knocking Occurred) During Operation
11-7. Cooling Water Temperature Too High
11-8. Exhaust Temperatures of All the Cylinders Too High
11-9. Engine Stopped Suddenly
(Volume:6pages)
11-2
11-1. Starting Failure
1) Flywheel not turned
2) Flywheel turned, but ignition not taken place
Cause Countermeasure
(1) Starting air pressure insufficient Fill the starting air tank with air.
(2) Engagement / disengagement switch actuated
(Turning gear set at the intermeshing position)
Disengage the turning gear.
(3) Malfunction of air motor
1.Voltage drop of air motor battery Charge the battery.
2.Malfunction of air motor pilot solenoid valve Press the manual starting push button to
start the engine.
(4) Engagement / disengagement switch actuated.
(Start / stop lever set in the STOP position)
Set the start / stop lever at the RUN posi-
ton.
(5) Too high viscosity of lubricating oil Warm up the engine or change the cur-
rent lub. oil with a low-viscosity one.
(6) Seizure of moving part
1.Seizure of piston and cylinder liner Check and repair the piston and cylinder
liner, or replace them.
2.Seizure of main bearing and / or camshaft bearing Check and repair the pertinent main
bearing or camshaft or camshaft bearing,
or replace it.
(1) Fuel oil not sent under pressure to fuel injection
pump
1.Fuel tank empty Supply the fuel to the fuel tank.
2.Clogging of fuel oil pipe (improper opening and
closing of each valve)
Check the opening and closing status of
each valve.
3.Clogging of fuel oil filter Clean the filter.
4.Failure of fuel feed pump Check and repair the pump.
5.Air entry through each joint Check and repair each joint, then bleed
air.
(2) Malfunction of sopping air piston Check and repair the air piston.
(3) Defect of fuel injection pump
1.Sticking of plunger and plunger guide Check and repair the plunger or plunger
guide, or replace it.
2.Wear or seizure of plunger guide Replace the plunger.
3.Improper assembling (deviation of match marks) Overhaul and check the pump.
(4) Defect of fuel injection valve
1.Sticking or seizure of needle. Check and repair the needle, or replace
it.
2.Breakage of nozzle spring Replace the nozzle spring.
3.Fuel injection pressure dropped Regulate the pressure.
4.Oil leakage from nozzle excessive Check and clean the mating surfaces of
nozzle and body, or replace the nozzle.
5.Breakage or improper clamping of high-pressure
fuel pipe
Replace the high-pressure fuel pipe, or
correct clamping.
(5) Malfunction of governor (loose governor link and
worn spline
Check and repair the governor, or
replace it.
(6) Poor airtightness of suction / exhaust valve
1.No clearance at head of suction / exhaust valve Adjust the valve head clearance.
2.Sticking of suction / exhaust valve Grind or replace the valve.
3.Damage of seat of suction / exhaust valve Grind or replace the valve seat.
(7) Too low cetane number of fuel Use a high- quality fuel oil.
1998.4.21R
11-3
11-2. Rotational Speed Dropped Spontaneously
11-3. Output of Each Cylinder not in Uniformity. (Dispersion of the
maximum combustion pressure and exhaust temperature is large
among cylinders.)
11-4. Bad Color of Exhaust Gas
(1) Clogging of fuel oil filter Clean the filter.
(2) Seizure of moving part (piston, main bearing or tur-
bocharger)
Check and repair the pertinent moving
part, of replace it.
(3) Air mixed in fuel oil pipe system Check and repair the fuel oil pipe system,
then bleed air.
(4) Moisture content in fuel oil Drain the filter, tank, etc.
(5) Defect of fuel injection pump Check and repair the pump, or replace it.
(6) Defect of fuel injection valve Check and adjust the valve, or replace it.
(7) Malfunction of governor Check and adjust the governor, or
replace it.
(1) Air mixed in fuel oil pipe system Check and repair the fuel oil pipe system,
then bleed air.
(2) Moisture content in fuel oil Drain the filter, tank, etc.
(3) Fuel injection volume not in uniformity among cylin-
ders
1.Nonuniform position of fuel injection pump racks Check the position of fuel injection pump
racks, then adjust it.
2.Sticking or wear of fuel injection pump plunger Check and repair the plunger, or replace
it.
3.Defect of fuel injection valve Check and repair the valve, or replace it.
4.Looseness or damage of fuel injection pipe Check and repair the pipe, or replace it.
5.Sticking of suction / exhaust valve or damage of
suction / exhaust valve seat
Check and repair the pertinent valve or
valve seat, or replace it.
6.Damage of fuel cam, or damage of suction /
exhaust cam
Check the fuel cam or suction / exhaust
cam, then repair it, of replace it.
(1) Improper injection timing Check and adjust the timing.
(2) Defect of fuel injection valve (fuel injection pressure
drop, sticking of nozzle)
Check the valve, then regulate the pres-
sure, or replace it.
(3) Defect of fuel injection pump Check the pump, then repair it, or
replace the pertinent valve sect.
(4) Improper adjustment of suction / exhaust valve
head clearance or damage of suction / exhaust
valve seat
Adjust or correct the clearance, or
replace the pertinent valve sect.
(5) Sticking of suction / exhaust valve Overhaul the suction / exhaust valve, and
then correct it.
(6) Damage of suction / exhaust cam Replace the camshaft.
(7) Defect of turbocharger
1.Clogging of filter Wash the filter.
2.Fouling of the blower side or turbine side Overhaul and wash the turbocharger /
blower.
(8) Fouling of boost air cooler (too high temperature of
boost air)
Overhaul and clean the air cooler.
(9) Shortage of fuel oil Use a high-quality fuel oil.
(10) Overload Reduce the load.
11-4
11-5. Lub. Oil Pressure Dropped below the Specified Pressure.
11-6. Unusual Sounds Heads (Knocking Occurred) During Operation
11-7. Cooling Water Temperature Too High
(1) Looseness of lub. oil pipe and cylinder block oil
hole plug
Check and repair the lub. oil pipe and
each oil hole plug.
(2) Clogging of lub. oil strainer Overhaul and clean the strainer.
(3) Excessive clearance of crankshaft bearing Check the clearance, then replace the
metal.
(4) Sticking of lub. oil pressure regulating valve or
loose adjusting bolt
Check the valve and bolt, then repair or
adjust the pertinent part.
(5) Sticking of lub. oil safety valve Check the valve and bolt, then repair it.
(6) Too high temperature of lub. oil
1.Shortage of cooling water volume Check the cooling water pump.
2.Fouling of lub. oil cooler Check the cooler, then over haul and
clean it.
3.Excessive blow-bye (gas leak) into the crank-
case
Check the piston rings and cylinder
liner.
4.Sticking of piston of lub. oil thermostatic valve
or defect of its element
Check the piston and element, then
repair or replace the pertinent part.
(7) Air sucked in lub. oil pump (shortage of lub. oil
volume)
Replenish the lub. oil.
(1) Excessive clearance of bearing of crankshaft of
camshaft
Check the clearance, then replace the
pertinent bearing.
(2) Loose bolts
1.Connecting rod bolts Check the connecting rod and bolts,
then retighten the bolts or replace
them.
2.Flywheel clamping bolts Check the bolts, then retighten them,
or replace them.
(3) Improper adjustment of suction / exhaust valve
head clearance or loose bolt
Check the clearance and bolt, then
adjust the clearance.
(4) Improper adjustment of fuel injection timing Check the timing, then adjust it.
(5) Fuel injection volume excessive
1.Malfunction of fuel injection pump Check and repair the pump, or replace
it.
2.Defect of fuel injection valve Check and repair the valve, then adjust
it.
(6) Increase of gear backlash or wear of gear bear-
ing
Check and adjust the gear or its bear-
ing, or replace it.
(1) Shortage of cooling water volume Check and repair the cooling water
pump.
(2) Sticking or defect of cooling water thermostatic
valve
Check or replace the thermostatic
valve.
11-5
11-8. Exhaust Temperatures of All the Cylinders Too High
11-9. Engine Stopped Suddenly
(1) Boost air temperature too high
1.Boost air cooler cooling water temperature too
high
Check the cooling water system, and
lower the cooling water temperature to
the specified range.
2.Shortage of boost air cooler cooling water vol-
ume
Check and repair the cooling water
pump.
3.Fouling of boost air cooler (cooling water side &
air side)
Overhaul and wash the cooler.
4.Engine room internal temperature too high Check and service the engine room
ventilation equipment.
(2) Boost air pressure too high
1.Clogging of turbocharger filter Wash the filter.
2.Clogging of boost air cooler (air side) Overhaul and wash the cooler.
3.Fouling of turbocharger (turbine side & blower
side) or its damage
Wash the blower side or overhaul and
wash the turbocharger, or replace it.
4.Rise of back pressure at exhaust port Check and clean the exhaust manifold
and exhaust pipe.
5.Engine room put under a negative pressure Check and service the engine room
ventilation equipment.
(3) Unsuitable properties of fuel oil Judging from the property analysis
results, change the fuel oil if necessary.
(4) Overload Reduce the load.
(1) Protective device switched on
1.Overspeed
Check the switch, then repair the
defective part. If necessary, replace
the pertinent part.
2.Lub. oil pressure drop
3.Temperature rise of cooling water excessive
(2) Governor or governor gear Check the governor and governor gear,
then repair or replace the pertinent
part.
(3) Fuel tank empty Replenish the fuel oil.
(4) Air mixed in fuel oil system Bleed air from the filter and oil pipe.
(5) Clogging of fuel oil filter Overhaul and clean the filter.
(6) Seizure of interlocking part (piston, main bear-
ing, crank-pin bearing, timing gear, etc.)
Check and repair the pertinent part, or
replace it.
11-6
MEMO
C

Request
Though this Parts List has been edited to

serve also as the appended figures of the
pertinent. Opefation Manual, any Part No.
thereof is subject to a chamge without notice.
Consequently, when you ate in need of a
particular Part, kindly place your order of that
Partwuth your nearest YANMAR Parts Selling
Agent, writing clearly Model and Mfg. No. of
your engine together with Part Name and Part
No. of the Part in demand.
Example of item & indication necessary at the

time of ordering Yanmar engine parts.
1 6N18AL-DV Engine Model 6N18AL-DV
3701FSF Engine Mfg. No. 3701FSF
Part Name Piston Ass'y
746674-22011 Part No. 746674-22011
1 set Q'ty Req'd 1 set

1 Fig 1 CYLINDER HEAD ASS'Y
2 Fig 2 VALVE ROTATOR ASS'Y
3 Fig 3 INDICATOR COCK ASS'Y
4 Fig 4 VALVE MECHANISM
5-1 Fig 5-1 CYLINDER BLOCK SIDE COVER ASS'Y
5-2 Fig 5-2 CYLINDER BLOCK SIDE COVER ASS'Y,
with lub. oil filler
5-3 Fig 5-3 CYLINDER BLOCK SIDE COVER ASS'Y,
with safety valve
6 Fig 6 CYLINDER LINER ASS'Y
7 Fig 7 MAIN BEARING ASS'Y
8 Fig 8 TURNING DEVICE
9 Fig 9 PLATFORM ASS'Y
10 Fig 10 CAMSHAFT & BUSH ASS'Y
11
Fig 11 CAMSHAFT & LUB. OIL PUMP DRIVING

IDLE GEAR ASS'Y
2005. 12.22R 6N18(A)L-V
12 Fig 12 COOLING WATER PUMP DRIVING IDLE
GEAR ASS'Y
13 Fig 13 TACHOMETER DRIVING DEVICE ASS'Y
14 (YPC-37 ) Fig 14 AIR COOLER ASS'Y,
YPC-37 type
15 Fig 15 AIR COOLER CASING ASS'Y
16-1
(RH133-Y
Fig16-1 TURBOCHAGER & EXHAUST GAS OUTLET
PIPEASS'Y,
equipped with RH133-Y type
16-2
RH143-Y
Fig16-2 TURBOCHAGER & EXHAUST GAS OUTLET PIPE
ASS'Y,
equipped with RH143-Y type
16-3
(RH133-Y
Fig16-3 TURBOCHAGER BLOWER WASHER,
RH133-Y type
16-4
RH143-Y
Fig16-4 TURBOCHAGER BLOWER WASHER,
RH143-Y type
17 Fig 17 EXHAUST MANIFOLD ASS'Y
18-1
(
Fig18-1 CRANKSHAFT & FLYWHEEL ASS'Y,
direct coupling & side bearinng spec.
18-2
(
Fig18-2 CRANKSHAFT & FLYWHEEL ASS'Y,
direct coupling & both side bearinng spec.
18-3
(
Fig18-3 CRANKSHAFT & FLYWHEEL ASS'Y ,
bell mounting spec.
19 Fig 19 PISTON & CONNECTING ROD ASS'Y
20 Fig 20 LUBRICATING OIL PUMP ASS'Y
21-1
(
Fig21-1 LUBRICATING OIL COOLER ASS'Y,
sea water spec.
21-2
(
fresh water spec.)
21-3
(
coolong of line system
21-4
(
cooling of lines system
22-1
(
Fig22-1 LUBRICATING OIL PRESSURE REGULATING
VALVE ASS'Y,
priming line of low pressure type
22-2
(
Fig22-1 LUBRICATING OIL PRESSURE REGULATING
VALVE ASS'Y,
priming line of high pressure type
23-1 Fig23-1 LUBRICATING OIL STRAINER ASS'Y,
notch-wire type
23-2

Fig23-2 LUBRICATING OIL STRAINER ASS'Y,
paper element type for turbocharger
Front side non-driving for separate spec.
23-3

Fig23-3 LUBRICATING OIL STRAINER ASS'Y,
paper element type for turbocharger
Front side driving for separate spec.
2005.12.22R
6N18(A)L-V
Item

Part
746674-22011
146674-22450
1 146674-22060
2 146603-22850
3 146673-22850
4 26206-080122
138613-23290
5 146673-22130
6 146673-22140
7 146673-22180
146673-22160
146673-22170
146673-22310
8 146673-22300
9 146673-22320
10 22252-000750
11 26911-100122
5 146674-22110
2008.9.30R
(3-face CR-plated)
(6) PISTON PIN

OIL RING, 3 3

(6)
If the piston top ring groove have

plating repaired piston
PISTON PIN ASS'Y
SLOTTED SET SCREW M1012
RETAINING RING, C type 75 12
6set
(6)
6s

75
PISTON ASS'Y
DO NOT USE THE 3-FACE-CR-PLATED

6

CAUTION
1
been repaired with Cr-plating.
PISTON ASS'Y
COMPRESSION RING, 2
Remark
In the case of piston ring groove

M1012

(6)
(6)
(24)
6

19
Fig.19 PISTON & CONNECTING ROD ASS'Y
Part Name
/

Quantity
/12
PISTON
COVER, cooling chamber / hole 12
COVER, cooling chamber / blind
(6)
6N18(A)L-V
COMPRESSION RING, 1
(1-face CR-plated)
6s
6s
6

(6)
TOP RING.
COIL EXPANDER
OIL RING ASS'Y

(24)
6
1 COMPRESSION RING, 1
2

TUBE, oil gallery
CUP WASHER
M812 BOLT M812
2
3
40
34.
Fig. 34 FUEL INJECTION PUMP ASSY
2008.3.13R
6N18(A)L-V
2
9
3
1
3
7
3
6
2 3
3
5
3
4
2
0
1
9
1
8
1
7
1
6
1
5
2
1
2
2
2
3
I
S
O
B
A
R
I
C

V
A
L
V
E

A
S
S
Y
2
4
1
2
1
1
3
1
4
2
7
2
6
6
9
3
3
3
2
1
3
3
2
,
3
3
2
7
4
0
3
8
3
9
2
8
3
0
2
5
5 4 8 7
1
1
1
0
58(6N18AL-EV)
Fig.58Boost Air Pressure Regulating Device (6N18AL-EV Type)
Item

Quantity

Part
Part Name
1set 746673-12150 BOOST AIR PRESSURE REGULATING
VALVE ASS'Y
1 1 140623-12302 BODY, regulating valve
2 1 140623-12312 PACKING
3 1 146673-12350 FLANGE
4 1 137602-12320 REGULATING VALVE ROD
5 M12 1 26706-120002 NUT M12
6 M1035 2 26206-100352 BOLT M1035
7 1 140623-12341 SILENCER
8 1 140623-12190 PACKING
9 M1065 2 26206-100652 BOLT M1065
10 1 146674-01610 AIR CHAMBER COVER
1 146673-01620 PACKING
M1225 2 26206-120252 BOLT M1225
2005. 3.16R 6N18AL-EV
1
1

Remove the elbow, loosen two nuts of the solenoid valve, turn
the coil housing (with sealed in black resin) counterclockwise
for loosening and remove it from the (aluminum) valve body.
Loosen the three screws and check that the valve port is not
clogged with impurities. If it is clogged, clean the port and
check the function of the valve again according to the
instruction of above.

Fig.2 Module for 100DVC Power
2006. 2. 13R
Page ATT-2

Fig.1 Module for 24DVC Power

(
Edition 12, April 2009
)
1/4
23
A
D
C
B
E
22
19
25
24
26
28
27
29
9
8
7
6
5
4
3
1
30
33
31
12
15
17
16
14
18
39
42
53
41 40
43
44
50
48
49 46
45
47
13
10
11
37
36
34
38
Greece
U.A.E
Hong Kong
China
Tokyo
Osaka
Taiwan
Philippinnes
32
21
20
51
Yanmar's Worldwide Service Network
Domestic Office Overseas Office
Yanmar (Head office)
Yanmar (Tokyo)
Export Dept. Marine
Large Power Products Operations Devision
1-32, Chayamachi, Kita-ku, Osaka, Japan 530-8311
Country Code: 81
Phone: 3-3275-4909 Fax: 3-3275-4969
Quality Assurance Dept.
Country Code: 81
Phone: 6-6489-8017 Fax: 6-6488-4009
1-1, 2-Chome, Yaesu, Chuo-ku, Tokyo, Japan
104-8486
1-1, 1-Chome, Nagasu Higashi-dori, Amagasaki,
Hyogo, Japan 660-8585
Yanmar Europe B.V. (YEU)
Brugplein 11, 1332 BS Almere-de Vaart, Netherlands
Country Code: 31
Phone: 36-5493200 Fax: 36-5493209
Tokyo Office (Head Office)
1-1-1, Shinbashi, Minato-ku, Tokyo, Japan 105-0004
Country Code: 81
Phone: 3-3508-1112 Fax: 3-3508-1123
Web: www.yanmar.co.jp/ye/
Osaka Office
1-1, 1-Chome, Nagasu Higashi-dori, Amagasaki,
Hyogo, Japan 660-8585
Country Code: 81
Phone: 6-6489-8048 Fax: 6-6481-6101
Web: www.yanmar.co.jp/ye/
A
Yanmar Asia (Singapore) Corp. Pte. Ltd. (YASC)
4 Tuas Lane, Singapore 638613
Country Code: 65
Phone: 6595-4200 Fax: 6862-5189
B
Yanmar America Corp. (YA)
951 Corporate Grove Drive, Buffalo Grove, IL 60089-4508, U.S.A.
Country Code: 1
Phone: 847-541-1900 Fax: 847-541-2161
C
Yanmar Engine (Shanghai). Co., Ltd.
Room 2002, China Insurance Building, 166
Pudong Lujiazui East Road, Shanghai, China
Country Code: 86
Phone: 21-5879-5090 Fax: 21-5879-8090
D
Yanmar Co., Ltd. India liaison Office
603, Maithili Signet Sector 30A, Opp Vashi Railway Starion
Vashi, Navi Mumbai 400703
Country Code: 91
Phone: (022)2781-0972, 2781-0975, 2781-0976
FAX: +91-22-2781-0977
E
Hong Kong Office
Room 1208, C.C. Wu Building, 302-308 Hennessy Road,
Wanchai, Hong Kong, China
Country Code: 852
Phone: 2833-9032 Fax: 2904-7783
Greece Liaision Office
5th Floor, 130, Sygrou Avenue, Athens, Greece
Country Code: 30
Phone: 210-922-2481 Fax: 210-922-2484
Philippines Office
6th Floor, YL Holdings Building, 115 V.A. Rufino Street
Corner Salcedo Street, Legaspi Village 1229, Makati City,
Philippines.
Country Code: 63
Phone: 2-893-2880 / 4262 Fax: 2-893-4339
2/4
Colombo Dockyard (Pte) Ltd.
SRILANKA
Graving Docks Port of Colombo, P.O.Box 906,
Colombo 15, Srilanka
Country Code: 94
Phone: 11-25224615 Fax: 11-2446441
1
ASIA
CHINA
TIANJIN PORT TUG-BOAT & LIGHTER COMPANY
/YANMAR ENGINE SERVICE CENTER
No.383 Yongtai Road, Tanggu District, Tianjin, China
Country Code: 86
Phone: 22-2570-7510 FAX: 22-2570-7510
4
DALIAN WANFANG MARINE TECHNOLOGY CO., LTD
No.40 Aixian Street, Qixianling, Dalian High-Tech
Industrial Zone, China
Country Code: 86
Phone: 411-84799000 FAX: 411-84795678
5
GOLTENS SHANGHAI CO., LTD
Block No.5, No.533 Yuanzhong Road, Nanhui
Industrial Zone, Nanhui District, Shanghai, China
Country Code: 86
Phone: 21-58186628 FAX: 21-58186633
3
Siam Consotium Service Co., Ltd.
THAILAND
103-107. Damronglatpipat Road, Klongtoey, Prakanong,
Bangkok, Thailand 10110
Country Code: 66
Phone: 2-249-8023 Fax: 2-249-7985
Yee Foo Marine Industrial Co., Ltd.
TAIWAN
6F-3, No.369 Fusing North Road, Taipei,
Taiwan ROC. 105
Country Code: 886
Phone: 2-8712-0848 Fax: 2-8712-0797
16
10
11
12
13
14
15
Seikoh Co., Ltd.
No.56 Yugang Jung 2 Rd., Chien Chen Dist. Kaohsiung, Taiwan
Country Code: 886
Phone: 7-831-2303 Fax: 7-882-3911
17 Seapowers Trading & Industrial services
PHILIPPNES
316-A Mamatid Cabuyao, Laguna, Philippines
Country Code: 63
Phone: 917-500-3017 Fax: 49-502-0765
E-mail: seapowers@pldtdsl.net
7
Cistar Tech HK Ltd.
HONG KONG
Y.T.M.L. No.44, Cha Kwo Ling Road, Yau Tong Bay,
Kowloon, Hong Kong, China
Country Code: 852
Phone: +85227750161 Fax: +85227726054
6
Pan Sarawak Co., Sdn. Bhd.
MALAYSIA
Wisma Pansar 23-27, Workshop Road 96007 Sibu
Sarawak, Malaysia
Country Code: 60
Phone: 84-333366 Fax: 84-314555
8
Chong Lee Leong Seng Enterprise Sdn. Bhd.
Lot 530, Persiaran Subang Permai Sg. Penaga
Industrial Park, USJ 1 47500 Subang Jaya Selangor
Darul Ehsan, Malaysia
Country Code: 60
Phone: 3-5632-1577 Fax: 3-5632-3126
9
Yanmar Jakarta Service Center C/O P.T.
Pioneer
INDONESIA
Jalan Ir. H. Juanda, No.40-41-42, Jakarta, Indonesia
(P.O. Box 2502-Jakarta 10025)
Country Code: 62
Phone: 21-385-8526 Fax: 21-384-8995
P.T. Pioneer
Jalan Ir. H. Juanda, No.40-41-42, Jakarta 10120, Indonesia
(P.O. Box 2502-Jakarta 10025)
Country Code: 62
Phone: 21-344-8486 Fax: 21-344-8995
INDIA
715, J.K. Chambers Sector 17, Vashi,
New Bombay-400 703. India
Country Code: 91
Phone: 22-55912233 / 27892524
Fax: 22-55912234 / 27892529
Chong Lee Leong Seng Co., (Pte) Ltd.
SINGAPORE
23 Tuas Avenue 2, Singapore 639454
Country Code: 65
Phone: 6264-2922 Fax: 6861-8785
KOREA
#136. 1-Ka, Dae kyo-Dong, Young Do-Ku, Busan, Korea
Country Code: 82
Phone: 51-412-6385 Fax: 51-414-8752
IND-AUST Maritime Pvt. Ltd.
Hwa Trading Co., Ltd.
Overseas Office
Overseas Service Agents
Dubai Liaison Office
Gold & Diamond Park, Manufacturing office 3006,
Ground Floor Building-3, Sheikh Zayed Road P.O
Box 214831 Dubai, U.A.E
Country Code: 971
Phone: 4-341-8787 Fax: 4-341-8778
Taiwan Branch
No.56, Yugangjung 2 Rd., Chienchen Dist, Kaohsiung, Taiwan
Country Code: 886
Phone: 7-815-4198 Fax: 7-815-3280
E-mail: mitsuru_kai@yanmardubai.ae
Liaison Office (Dongguan)
No.33, Jiaoyu Road, Banshi, Changping Town,
Dongguan, Guangdong, China
Country Code: 86
Phone: 769-8339-4935 Fax: 769-8339-7937
3/4
Mapso
ARAB REPUBLIC OF EGYPT
P.O. Box 2643, 44 Industrial Area, Cairo/Ismailia
Desert Road, Cairo, Egypt
Country Code: 20
Phone: 2-2962777 (8 lines) Fax: 2-2962780
27
Mapso-Alexandria Office
5 Orabi Street, Alexandria, Egypt
Country Code: 20
Phone: 3-483-3453 Fax: 3-483-3486
28
MIDDLE EAST
Saudi Diesel Generators Company Ltd.
P.O.Box 87, Dhahran Airport 31932, Saudi Arabia
Country Code: 966
Phone: 857-6769 / 8028/8036 Fax: 857-4681
29
30 Albwardy Marine Engineering (L.L.C)
SAUDI ARABIA
Dubai Shipdocking Yard P.O. Box 6515 Dubai, U.A.E
Country Code: 971
Phone: 4-324-1001, 4-324-1561 Fax: 4-324-1005
Goltens Co. Ltd. Dubai Branch
Al Jadaf Ship Docking Yard P.O. Box 2811, Dubai, U.A.E
Coutry Code: 971
Phone: 4-324-1642 Fax:4-324-1963
U.A.E
31
Aalborg International S.A.
MOROCCO
Port De Peche, Agadir, Morocco
Country Code: 212
Phone: 844234 / 841346 Fax: 845273
32
AFRICA
IMS Engineering (Prz) Ltd.
124 Marine Drive Parden Eiland, 7420, South Africa
P.O. Box 63 Parden Eiland 7420
Country Code: 27
Phone: 21-511-8201 Fax: 21-511-6698
33
SOUTH AFRICA
Skandiaverken, S.A.
SPAIN
Po. Ind. Torrelarragoiti Parcela P7M, Pab. 1y2 48170
Zamunio Bizkaia SPAIN
Country Code: 34
Phone: +34 94 6880200 Fax: +34 94 6880216
24
Aras Makina Sanayi Mumessillik ve Ticaret Ltd Sirketi
TURKEY
Aydintepe Mh.Sahilyolu Cd. Denizciler Ticaret Merkezi
No.51. 34947 Tuzla-Istanbul, Turkey
Country Code: 90
Phone: 216-392-9211Fax: 216-392-8827
ITALY
NDI SRL
Via G.B. Guarini, 33, 157121 Livorno-Italy
Country Code: 39
Phone: 0586-429053 Fax: 0586-443606
00
MARAS E.H.F
ICELAND
Akralind 2 201 K-pavogur Iceland
Country Code: 354
Phone: 555-6444 Fax: 565-7230
23
24
25
26
Nippon Diesel Service
GERMANY
Hermann-Blohm-Str. 1 D-20457, Hamburg, Germany
Country Code: 49
Phone: 40-317710 Fax: 40-311598
22
Shipaid Diesel Services Ltd.
U.K.
Units, 1&2, Plot 10, Westminster Trading Estate,
Westminster Road, North Hykeham Lincoln, LN6 3QY
Country Code: 44
Phone: 1522-533990 FAX: 1522-695153
21
EUROPE
Nakhodka Ships Service Ltd.
RUSSIA
59, Nakhodka Avenue Nakhodka, Russia 692900
Country Code: 7
Phone: 423-66-2-38-12 Fax: 423-66-2-10-71
18
Nicoverken Holland B.V.
NETHERLANDS
Algerastraat 20, 3125 BS Schiedam, The Netherlands
Country Code: 31
Phone: 10-2380999 Fax: 10-2380988
19
Fuji Trading (Marine) B.V.
Kortenoord 2-8 3087 AR Rotterdam, The Netherlands
Country Code: 31
Phone: 10-429-8833 Fax: 10-429-5227
20
4/4
Metalock do Brasil Ltda
BRASIL
Rua Visconde do Rio Branco 20/26, 11013-030,
Santos, SP, Brasil
Country Code: 55
Phone: 13-3222-4686 Fax: 13-3222-4088
50
Cromwell S.A.
ARGENTINA
Carifornia 733 1168-Buenos Aires, Argentina
Country Code: 54
Phone: 1-301-4124 Fax: 1-302-7407
46
Arzen Corpopation S.A.
Av. De Mayo 1370 Piso 2 Of 15 1362 Buenos Aires, Argentina
Country Code: 54
Phone: 1-325-9585 Fax: 1-325-9586
47
Sociedad Maestaranga Yungay Ltda
CHILE
Jose Tomas Ramos 184 Casilla 906 Vaiparaiso, Chile
Country Code: 56
Phone: 214476 Fax: 211898
48
Diesel Motors Thno
Vevtas-Servicios 56-41 Colon n 2090 Casillia
206-Talcanuano, Chile
Country Code: 56
Phone: 544208 Fax: 542942
49
Caribbean Dockyard Ltd.
TRINIDAD AND TOBAGO
P.O. Box 1147, Port Chaguaramas, Trinidad, W.I.
Country Code: 1
Phone: 809-634-4239 / 4229 / 4378
Fax: 809-625-1215 / 809-674-1743
44
SOUTH AMERICA
Tsakos Industries Navales S.A.
Avda. Gral Rondeau 2023 Montevideo Uruguay
Country Code: 598
Phone: 94-83-36 Fax: 94-70-95
45
URUGUAY
NORTH AMERICA
39 Marine Turbo & Diesel Inc.
1090 7th Street, Richmond, Ca, 94801, U.S.A.
Country Code: 1
Phone: 510-236-3525 Fax: 519-236-3576
North Florida Ship Yards Inc.
P.O. Box 3255 Jacksonville, Florida 32206, U.S.A.
Coutry Code: 1
Phone: 904-354-3278 Fax:904-353-2665
U.S.A
40
41 International Five Star Marine Service Inc.
905 Willow Creek Drive La Porte, Texas 77571, U.S.A.
Country Code: 1
Phone: 713-473-8660 Fax: 713-473-8667
GOLTENS New York Corp.
160 Van Brunt Street, Brooklyn, NY 11231 U.S.A.
Coutry Code: 1
Phone: 718-855-7200 Fax: 718-802-1147
42
GOLTENS Miami Co. Inc.
2323 N.E. Miami CourtMiami, Florida 33137 U.S.A.
Coutry Code: 1
Phone: 305-576-4410 Fax: 305-576-3827
43
Waterside Engineering Pty. Ltd.
AUSTRALIA
48-50 Export Drive Brooklyn 3025, Victoria, Australia
Country Code: 61
Phone: 3-9314-3722 Fax: 3-9314-3799
36
Jaitco
10199 Kurraba Road, Neutral Bay, N.S.W. 2089, Australia
Country Code: 61
Phone: 2-99098545 Fax: 2-99531728
37
Japan Marine Engineering Co.,ltd
475 Warrigal Road Moorabbin Victoria Australia 3189
Country Code: 61
Phone: +61-3-9555-5277 FAX: +61-3-9555-5344
51
YANMAR AMERICA CORPORATION. NEW YORK BRANCH
Parker Plaza 16F, 400 Kelby Street, Fort Lee, NJ
07024 U.S.A.
Country Code: 61
Phone: 201-592-8500 FAX: 201-592-8503
52
Forgacs Cairncross Dockyard Pty. Ltd.
Thynne Road Morningside, Brisbane, Queensland 4170,
Australia
Country Code: 61
Phone: 7-322-70856 Fax: 7-3399-6164
34
OCEANIA
Lutheran Shipping
PAPUA NEW GUINEA
P.O. Box 1459, Lae, Papua New Guinea
Country Code: 675
Phone: 42-6190 FAX: 42-5806 Telex: NE 44172
38
History : 17th revision : August, 2004
18th revision : November, 2004
19th revision : January, 2005
20th revision : March, 2005
21st revision : August, 2005
22nd revision : January, 2006
23rd revision : December, 2006
25th revision : February, 2009
28th revision : June, 2009
OPERATION MANUAL
Issued by : Quality Assurance Dept.,
Large Power Products Operations Division
Yanmar Co.,Ltd.
Edited by : Yanmar Technical Service Co.,Ltd.
Model
NZ SERIES HYDRAULIC GOVERNOR
MODEL NZ61/NZ115
SERVICE MANUAL
I.B.C.No. 0BNZ6-G00100
2008.7.4R
Be sure to read this Operation Manual for you to use
this product safety and correctly.
Even after reading it, carefully keep it, making clear to
all personnel concerned where it is kept so that the
operator, mechanic or supervisor will have an access
to it whenever he wants to read or refer to it.
PREFACE NZ GOVERNOR
PREFACE
This Service Manual describes the construction, maintenance of, and disassembling procedures for Model
NZ61/NZ115 Hydraulic Governor and controller. Read this Manual carefully to use the governor correctly.
Keep this Manual under care at a clearly identified place accessible for the operator to refer to it at any
time.
The text and lustrations of this Manual may partly disagree with the actual product as depended on its
specifications.
Also note that parts used are subject to change for improving the quality and performance of or for rea-
sons of safety of this product.
Use our genuine parts or specified parts for replacement parts. Order a part to your nearest sales agent
or YANMAR parts sales agent. When ordering a part, clearly specify the Part Name (part description),
Part No., Engine Name and Governor Model and Serial No.
Should you have lost or damaged this Manual or if you have any question and advice, feel free to contact
us or your nearest sales or service agent (shown in the service network list YANMER Worldwide Ser-
vice appended to the Engine Operation Manual).
Precautions on Safety
A note prefixed with the or mark in this Manual is a very impor-
tant part of the text particularly in view of safety as it indicates that there is the possibility of resulting in
injury or serious damage to the product when an advice on handling or the proper precaution is not fol-
lowed. Thus, be sure to follow such a note.
An item prefixed with the mark in this Manual is very important for handling of a product. A failure to
observe such an item may incur a deterioration of performance or a trouble of this product. Therefore, be
sure to observe such an item.
An item prefixed with the mark in this Manual indicates a chapter, section, clause, page or docu-
ment to be referred to.
PREFACE NZ GOVERNOR
MEMO
CONTENTS NZ GOVERNOR
CONTENTS
Page
PREFACE
CHAPTER 1. GENERAL DESCRIPTION............................................................................................1-1
1-1. Specifications of the Governor .............................................................................................1-1
1-2. Hydraulic Oil .........................................................................................................................1-1
1-3. Cautions on Handling of the Governor .................................................................................1-1
CHAPTER 2. OUTLINE OF CONSTRUCTION ...................................................................................2-1
2-1. Function of Major Parts ........................................................................................................2-1
2-2. Operation of the Governor ...................................................................................................2-3
2-3. Speed Droop Adjusting Mechanism .....................................................................................2-4
2-4. Compensator Mechanism ....................................................................................................2-5
CHAPTER 3. MAINTENANCE INSPECTION......................................................................................3-1
3-1. Daily Inspection ....................................................................................................................3-1
3-2. Change of Hydraulic Oil .......................................................................................................3-1
3-3. Air Bleeding of Hydraulic Oil Passage ..................................................................................3-2
3-4. Speed Droop Adjustment .....................................................................................................3-3
3-5. Adjustment of Needle Valve .................................................................................................3-3
3-6. Cautions in Initial Run ..........................................................................................................3-4
3-7. Troubleshooting ...................................................................................................................3-6
3-8. Criteria on Parts Replacement .............................................................................................3-8
CHAPTER 4. REMOTE CONTROLLER..............................................................................................4-1
4-1. Motor Controller ....................................................................................................................4-2
4-2. Pneumatic Controller ............................................................................................................4-4
4-3. Wire Controller ......................................................................................................................4-7
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR ...........................................5-1
5-1. Cautions in Disassembly/Reassembly..................................................................................5-1
5-2. Development of the Governor ...............................................................................................5-2
5-3. Disassembly of the Governor................................................................................................5-4
5-4. Checking of Various Parts.....................................................................................................5-9
5-5. Reassembly of the Governor ..............................................................................................5-12
5-6. Service Data in Servicing....................................................................................................5-14
CONTENTS NZ GOVERNOR
MEMO
CHAPTER 1. GENERAL DESCRIPTION
1-1
NZ GOVERNOR
1-2. Hydraulic Oil
(1)The body of this governor comprises an oil
sump chamber, and thus the governor can
use an equivalent to the system oil for the
engine as governor hydraulic oil.
Don't use synthetic oil as hydraulic oil for
this governor. If used, it deteriorates oil
seals and packing much earlier than the
usual.
(2)Properly use the hydraulic oil according to the
governor oil temperature in a normal run.
1-3. Cautions on Handling of the Governor
(1)Do not install and handle the governor so that
a force is applied to or a shock is imparted to
the gear shaft, speed control shaft, and
terminal shafts.
Otherwise, the shafts might be bent, and
seals or internal parts might be damaged.
(2)When attaching the governor to the engine,
attach the governor to its driving device under
the governor's own weight while setting the
spline of the gear shaft, and uniformly tighten
tightening nuts.
Gov. Oil Temperature Hyd. Oil Viscosity
Below 50C SAE20
Between 50C and 70C SAE30
Between 70C and 80C SAE40
1-1. Specifications of the Governor
Specifications of the Models NZ61 & NZ115 Governors are as follows:
(A): for Engine Model 6N160 & 6N165 .
(B): for Engine Model 6N18 & 6N21.
Sectional view of the governor and nomenclature of its major parts are shown in Fig. 1-1.
Governor Model Unit
NZ61
NZ115
(A) (B)
Governor controlling force (work done) Nm(kgfm) 5.9 (0.6) 9.8(1.0)
Output shaft torque Nm(kgfm) 9.8(1.0) 11.8(1.2) 14.7(1.5)
Hydraulic oil pressure MPa (kgf/cm
2
) 1.18(12) 1.47(15) 1.47(15)
Power piston diameter (minor/major) mm 17.6/25 18.6/27
Setting speed droop adjustment range % 0~10
Dry mass kg About 5.5
(Volume:2pages)
1-2
NZ GOVERNOR

024659-00E
Speed Control Shaft
Floating Lever
Terminal Shaft
Terminal Arm
Droop Adjuster
Power Piston
Housing
Compensator Rod
Compensator Piston
Needle Valve
Base
Gear Shaft
Governor Weight
Governor Spring
Pilot Valve
Pilot Valve Bushing
Nomenclature of the Governor Major Parts
Fig. 1-1
CHAPTER 2. OUTLINE OF CONSTRUCTION
2-1
NZ GOVERNOR
(1) Gear Shaft
Being an input shaft for the governor, the gear
shaft serves as a gear to drive the hydraulic oil
pump.
(2) Pilot Valve Bushing
The part intermeshing with the gear shaft consti-
tutes the hydraulic oil pump gear, the flyweight
assembly is fitted to the upper part, and the pilot
valve is fitted to the inner part. Besides, a hydrau-
lic oil passage hole to the power piston is pro-
vided to this bushing.
(3) Governor Weight
Rotating together with the pilot valve bushing
according to the rotation of the gear shaft the gov-
ernor weight moves the pilot valve vertically
according to a change in the engine speed.
(4) Pilot Valve
The governor spring is incorporated into the
upper part of the pilot valve, and it moves verti-
cally according to a change in compressive load
of the spring and an opening or closing of the gov-
ernor weight.
A vertical movement of the pilot valve controls the
hydraulic oil which flows to the lower part of the
power piston as the control land at the central part
opens or closes the hydraulic oil passage hole in
the pilot valve bushing.
(5) Floating Lever
Coupled to the speed control shaft through the
spring fork and a fork, the floating lever is con-
nected to the power piston through the droop
adjuster and the terminal arm.
(6) Power Piston
The hydraulic oil pressure bearing area ratio of
the power piston upper and lower parts is 1 : 2,
and the power piston is actuated vertically by sup-
ply of hydraulic oil from the pilot valve bushing
central hole or discharge of the oil.
Besides, the compensator spring and compensa-
tor rod are incorporated in the inner part of the
piston.
024660-00E
Power Piston
Compensator Rod
Compensator Spring
Compensator Spring
Compensator Piston
(Upper)
(Lower)
Needle Valve
Gear Pump
Gear Shaft
Pilot Valve
Pressure Regulating Valve
Pilot Valve Bushing
Governor Weight
Governor Spring
Spling Folk
Speed Control Shaft
Fork
Floating Lever
Terminal Shaft
Droop Adjuster
TerminalArm
This Chapter describes the functions of major parts that are constituting the governor and principle of its
operation.
2-1. Function of Major Parts
Fig. 2-1
(Volume:6pages)
2-2
NZ GOVERNOR
(7) Terminal Arm
Coupled to the power piston by the guide lever.
the terminal arm transmits a movement of the
power piston to a fuel injection pump through the
linkage. A droop adjuster to adjust the speed
droop is also mounted to this arm.
(8) Droop Adjuster
Incorporated in the terminal arm, the droop
adjuster changes the speed droop by adjusting its
mounting position.
Sec. 2-3. Speed Droop Adjusting Mechanism
(9) Needle Valve
The needle valve adjusts the compensator effect
by regulating the hydraulic oil pressures of the
compensator case and the pilot valve lower case.
Sec. 2-4. Compensator Mechanism
(10) Pressure Regulating Valve
It regulates the hydraulic oil discharged from the
hydraulic oil pump to the specified pressure.
2-3
NZ GOVERNOR
2-2. Operation of the Governor
Fig. 2-2 shows the system diagram on operation
of the governor.
Balancing a compressive force of the governor
spring with a centrifugal force of the governor
weight, the governor operates to maintain a fuel
injection volume corresponding to the load of the
engine.
1) Starting
The governor weight is closed by the governor
spring, and the control land of the pilot valve is
located below the control port. As the engine is
started, the hydraulic oil is sent into the upper and
lower parts of the power piston at the same time.
Since the hydraulic oil pressure bearing area ratio
of the power piston upper and lower parts is 1 : 2,
the power piston shifts upward (in the direction of
fuel increase) to facilitate starting.
2) Steady Running
Under the stable state of the engine load, a com-
pressive force of the governor spring balances
with a centrifugal force of the governor weight the
control land closes the control port and the power
piston holds a fixed position to set the engine
rotation.
3) Load Increasing
As the load increases, the engine rotation drops,
and a centrifugal force of the governor weight
decreases to close it.
The control land shifts below the control port, the
hydraulic oil is sent into the lower part of the
power piston to shift it upward (in the direction of
fuel increase). As the power piston shifts up-ward,
the governor spring is also pulled upward through
the droop adjuster and the floating lever that are
incorporated in the terminal arm, and the control
land closes the control port to rise the speed in
correspondence to the increased load and thus to
maintain the equilibrium.
Inflow
Dec.
Inc.
Gov. Spring com-
pressive force
Engine
Speed
Centrifugal foce
(gov, wt. open/close)
Dec.(close)
inc.(open)
Dec.
Inc.
Decrease
Load
Increase
Inj. dec.
Inj. inc.
Fuel Pump
Speed Control Shaft
Link Mech
Floating Lever
Return pilot valve
to its formerpos.
Dish.
Hyd. Oil
Control Port
Terninal Shaft
Disch.
Oil Sump
Chamber
Hi-pres. Hyd.Oil
Pres.Reg. Valve
Gear Pump
Fall
Fall
Rise
Rise
Control Land
Pilot Valve
Droop Adjuster
024661-00E
Fig. 2-2
2-4
NZ GOVERNOR
4)Load Deceasing
Contrary to the operation in a load increase, the
control land shifts above the control port. The
hydraulic oil is discharged from the lower part of
the power piston, and the power piston shifts
downward (in the direction of fuel decrease).
2-3. Speed Droop Adjusting Mechanism
This mechanism purports to adjust the
speed droop and can set any droop within
the range of 0 to 10 %.
The lever ratio (L1/L2) of the floating lever change
by changing the position of the droop adjuster, the
set load (compressive force) of the governor
spring also changes, and consequently, the
speed droop undergoes a change.
A relation between the set positions of the droop
adjuster and the speed droop becomes as fol-
lows:
NOTE: The droop adjuster set graduation does
not mean to indicate a value of the speed
droop (variation).
It indicates in percentage the difference bet-
ween the set speed (N2) following the risen
speed when the load is shut off (0%) and the
speed(N) in the 100% load.
Time of stabilize
It refers to a time required to achieve the set
speed from a moment the load is shut off.
It indicates in percentage the difference bet-
ween the most risen speed (N1) on the way to
become the stable speed when the load is shut
off (0 %) and the speed (N) in the 100 %
Droop
adjuster set
graduation
0 12
Speed droop
(variation)
Decreases Increases
Permanent variation = x 100 (%)
N2- N
N
Momentary variation = x 100 (%)
N1- N
N
024662-00E
L1
L2
Floating Lever
Speed Control Shaft
Droop Adjuster
Terminal Arm

Droop Adjuster
Setscrew
Governor Spring Power Piston
N
N1
N2
024663-00E
Time of stabilize
100
0
Load (%)
RPM
(for Frequency)
Fig. 2-3
Fig. 2-4
2-5
NZ GOVERNOR
2-4. Compensator Mechanism
This mechanism consists of the compensator
upper and lower springs and compensator pis-
ton that are incorporated in the power piston
as well as the needle valve. Besides, the com-
pensator case is connected to the pilot valve
lower case with the hydraulic oil passage, and
they are led to the oil sump through the needle
valve.
When the engine set rotation is changed or
the engine load fluctuates, this mechanism
stabilizes the governor operation by the mini-
mum overshoot or undershoot.
As the engine rotational setting is changed or
the load fluctuates, the power piston operates
to change the fuel injection volume.
At that time, the compensator piston also oper-
ates simultaneously, but a pressure generates
temporarily in the compensator case. This
pressure acts in the reverse direction to the
movements of the power piston and pilot valve
and thus assists in early restoring to the steady
state.
The magnitude of a positive or negative pres-
sure of the compensator case and pilot valve
lower case may vary according to the opening
of the needle valve and requires a proper
adjustment of the opening.
Chapter3, Sec. 3-5. Adjustment of Needle Valve
If the needle valve is closed too firmly, the
governor becomes dull and the response by
the engine is delayed in a load fluctuation.
Moreover, if opened too extensively, the
engine rotation becomes unsteady.
Seed setting Rise Drop
Load fluctuation Increase Decrease
Pilot Valve Fall Rise
Power Piston Rise Fall
Compensator
CasePilot valve
lower case
Positive
pressure
Negative
pressure
Compensator
spring
Lower spring
compression
Upper spring
compression
Needle Valve
Compensator
Case
Compensator
Piston
Pilot Valve
Pilot Valve Lower Case
Compensator
Upper SPring
Compensator
Lower SPring
Power Piston
024664-00E
Fig. 2-5
2-6
NZ GOVERNOR
MEMO
CHAPTER 3. MAINTENANCE INSPECTION
3-1
NZ GOVERNOR
3-1. Daily Inspection
1) Inspection prior to starting
(1)Once a day check the oil level of the oil gauge.
The specified oil level is a level 2 to 3 mm
above the center of the oil gauge.
In the case where the oil level fails, check if
there is an oil leakage.
(2)Check for looseness of bolts and nuts of vari-
ous parts and if there is an abnormality of a
linkage that connects the governor with a fuel
injection pump.
2) Inspection during a run
(1)Measure the temperature of the governor
housing with use of a thermometer.
The temperature becomes stable if the engine
is run for 30 to 40 minutes.
If the temperature rises to above 80C, there
will be an abnormality. Thus, make a check.
(2)Check for any abnormal noise.
3-2. Change of Hydraulic Oil
Change the hydraulic oil first in 1,000 hours or
three months and subsequently in 3,000 hours or
every six months with the new one.
An oil volume to reach the specified oil level is
about 1.3 liter.
When changing the hydraulic oil, have the
start/stop lever of the engine set in the STOP
position D so as not to start the engine by
mistake.
This Chapter describes the routine maintenance inspection, basic adjustment and troubleshooting of the
governor.
Fig. 3-1
Oil Filler
Oil Gauge
Oil Filler
Oil Filler
024665-00E
(Volume:8pages)
3-2
NZ GOVERNOR
Detach the drain plugs and needle valve from
the governor base to discharge the oiil hydrau-
lic oil.
Detach the needle valve only after checking its
setting, its position opened from its completely
closed state by how many turns.
Detach the cover, and check if sludge is accu-
mulated in the governor oil sump.
Attach the drain plugs and needle valve, pour
in the new hydraulic oil, and attach the cover.
When the hydraulic oil is changed, be sure to
bleed the air.
3-3. Air Bleeding of Hydraulic Oil Passage
Bleed the air from the hydraulic oil passage
according to the following procedures:
(1) Set the needle valve in the fully opened setting
(three turns back from the completely closed
state).
(2) Turn the control knob to set the speed control
shaft pointer with the SPEED graduation 0,
and start the engine.
(3) Run the engine at a low speed to let hunting or
surging, and run it further for about 30 sec-
onds.
Do not run the engine in the range of torsional
vibration critical speed.
(4) Slowly close the needle valve to set it in the
specified position.
In case where air bleeding is insufficient
hunting may not be stopped. In that case,
open the needle valve again to let hunting.
Whenever the governor is replaced; ser-
viced or repaired, adjust the needle valve.
Sec. 3-5. Adjustment of Needle Valve
(5) In case where the oil level drops, feed the gov-
ernor with hydraulic oil.
FUEL SPEED
0
0
2
2
4
4
6
6
8
8
10
Contol Knob
Needle Valve
PENUMATIC CONTROLLER
Control Knob
MOTOR CONTRALLER
Control Knob
024667-00E
Drain Plug
Drain Plug
CLOSE
OPEN
Needle Valve
Oil Gauge
024666-00E
Fig. 3-2
Fig. 3-3
3-3
NZ GOVERNOR
3-4. Speed Droop Adjustment
Adjust the speed droop to change it according to
the following procedure:
(1) Remove the (controller) cover, and change the
set position of the droop adjuster.
As the adjuster graduation is shifted in the "0"
direction, the speed droop lessens.
As the adjuster graduation is shifted in the
"10" direction, the speed droop enlarges.
(2) Attach the cover, run the engine, and while
measuring the speed droop, change the set
position of the droop adjuster until the aimed
speed droop is reached.
Each time the set position of the droop
adjuster is changed, readjust the needle
valve.
3-5. Adjustment of Needle Valve
The needle valve serves to adjust the response
characteristics of the governor. If the needle valve
is properly adjusted, the engine maintains the fuel
injection volume after a change in load with the
minimum rotational fluctuation and time.
The needle valve has been adjusted to fit with the
engine individually. In the following cases, the
needle valve has to be adjusted:
In case where the governor is replaced or
serviced.
In case where the governor is overhauled
(disassembled and repaired).
When the viscosity of hydraulic oil is
changed.
In case where a linkage which connects the
governor with a fuel injection pump is
altered.
In case where the set position of the droop
adjuster is changed.
(1) After the air bleeding of the governor and set-
ting of the droop adjuster are finished, run the
engine as well as the governor until they
assume the usual running state.
As the engine is run at the no-load rated
speed for 30 to 40 minutes, the viscosity of
hydraulic oil stabilizes in the usual running
state.
(2) Set the needle valve in the widest opened
state possible within a range the engine can
run with steady speed .
In case of generator driving, set the needle
valve under the rated speed state of the
engine.
In case of a main marine engine or driving a
pump, for instance, set the needle valve
under the minimum speed state of the
engine within its normal service range.
If the needle valve is closed too firmly, the
governor becomes dull and the engine's
response to a load change is delayed.
0
1
Droop Adjuster
Needle Valve 024668-00E
Fig. 3-4
3-4
NZ GOVERNOR
3-6. Cautions in Initial Run
1) Mounting of the governor
While setting the governor with spline of the gear
shaft, mount the governor under its own weight.
2) Oil feeding
(1) Feed the governor with new hydraulic oil to a
level 2 to 3 mm above the center of the oil
gauge.
(2) Move the governor vertically until the terminal
arm becomes heavy, and bleed the air from
the power piston and hydraulic oil passage.
(3) If the oil level drops, replenish the hydraulic oil
up to the specified oil level.
3) Connection of the linkage
Check if a linkage that connects the governor
with a fuel injection pump has been fitted
properly.
A poor connection of the linkage has a possi-
bility of being related to abrupt rotation of the
engine.
(1) Set the start/stop lever of the engine in the
STOP position.
(2) Fit the output lever to the terminal shaft of the
governor, and connect a linkage.
(3) Turn the terminal shaft fully in the FUEL
graduation 0 direction, and secure]y tighten
the clamping bolt oft he output lever.
The terminal shaft pointer should indicates
the 0.
The rack of a fuel injection pump should be
in the no-injection position.
(4) Shift the start/stop lever of the engine in the
RUN position, and then check if the output
lever moves lightly when it is shifted from the
0 to 8 terminal shaft graduation.
024669-00X
FUEL
0
+
0
2
4
6
8
10
8
2
6
4
SPEED
Output Lever
024670-00E
Fig. 3-5
Fig. 3-6
In the shipping of your engine from our shop, the governor has been adjusted and fed with hydraulic oil.
However, in case where the governor is replaced, serviced or repaired, observe the following matters in
the initial run:
3-5
NZ GOVERNOR
4) Setting Of speed droop
Since the droop adjuster graduation of the new or
serviced governor has been set in the "5", tempo-
rarily set the droop adjuster, referring to the for-
mer governor or the adjuster graduation prior to
the repair.
5) Setting of the controller
Turn the control knob to set the speed control
shaft pointer in the SPEED graduation "0".
6) Start the engine according to Operation
Manual for the engine.
Be sure to start the engine on the engine
side, and have it ready so that it can be
stopped at once.
Should abrupt rotation break out there is a
possibility of damaging the engine or causing
an accident resulting in injury or death.
7) Adjustment of the droop adjuster and nee-
dle valve.
Adjust the droop adjuster and needle valve.
Sec. 3-4. Speed Droop Adjustment
Sec. 3-5. Adjustment of Needle Valve
3-6
NZ GOVERNOR
3-7. Troubleshooting
Nature of
Trouble
Probable Cause Countermeasure on
Governor/Controller
Engine Side Governor/Controller Side
Engine
rotation
fluctuated
periodically
(hunting)
Load in fluctuation
Fuel feed pressure too
high (or too low)
Uneven combustion
Fuel oil filter fouled
Air intruded into fuel oil
Fuel injection pump
rack malfunctioned
Linkage twisted or
jolted extensively
Linkage wrongly
connected (in case the
governor is detached
from the engine)
Needle valve opened too widely Adjustment of the needle valve
Power piston stuck or malfunctioned Overhaul cleaning or servicing
Pilot valve malfunctioned Overhaul cleaning or servicing
Oil leaked inside the governor Servicing (replacement of worn
parts)
Tip of governor weight (face con-
tacting the thrust washer) worn
away
Replacement of the governor
weight assy.
Compensator piston malfunctioned Servicing
Hydraulic oil passage of compen-
sator mechanism blocked up
Overhaul cleaning
Rotational
restoration
lagged
against the
load fluctu-
ation of the
engine or
reaction to
a change in
clogged
Engine overloaded
Fuel oil filter fouled or
clogged
Fuel injection pump
rack stuck
Linkage stuck
Needle valve closed too tightly Adjustment of the needle valve
Compensator piston stuck Overhaul cleaning or servicing
Needle valve clogged Cleaning oft he needle valve
Hydraulic oil passage of compen-
sator mechanism blocked up
Overhaul cleaning
Hydraulic oil pressure dropped
(Side clearance of hydraulic oil pump
Servicing (replacement of worn
parts)
Pressure regulating valve stuck Overhaul cleaning
[Motor Controller]
Friction clutch slipped
Shim adjustment of the friction
clutch
[Pneumatic Controller]
Air leaked from diaphragm
Push rod malfunctioned
Leakage correction or replace-
ment of the diaphragm
Correction of the push rod
[Wire Remote Control]
Clearance of the wire coupling too
large
Coupling correction of the
remote control wire
[Miss operation]
Speed control shaft bent or mal-
functioned
Terminal shaft malfunctioned
Servicing
Servicing
A trouble of the governor normally appears as a speed change of the engine, but it is practically impossible
to forecast all kinds of troubles.
This Chapter outlines the most general troubles of the governor.
A speed fluctuation and an unsatisfactory control are caused either by a trouble on the engine side or a
trouble of the governor or controller.
Since the governor uses a large number of precision parts and there is a danger of overrunning the
engine if parts are wrongly incorporated or setting is improperly done, do not repair the governor in the
field, but consult your nearest sales agent or service agent (shown in the service network list "YAN-
MAR Worldwide Service appended to this Engine operation Manual) for repair of your governor.
3-7
NZ GOVERNOR
Fuel injec-
tion pump
rack
frequently
inched
( jiggling)
Backlash of the gover-
nor driving system gear
too large
Influenced by torsional
vibration
Governor poorly mounted
(Gear shaft and spline coupling
poorly centered )
Correction of governor mount-
ing
Governor weight malfunctioned Replacement of the governor
weight assy.
No output
from the
governor
(the output
lever could
not be
moved)
Spline of the governor
driving device worn off
Linkage stuck
Output lever clamping
bolt loosened
Power piston stuck
[Oil pressure of the governor not
produced]
Pressure regulating valve stuck or
damaged
Side clearance of the pump gear
too large
Overhaul cleaning
Overhaul cleaning or replace-
ment
Overhaul cleaning or servicing
(replacement of worn parts)
Governor
hydraulic oil
decreased
Oil seal damaged or gear shaft
worn away
Replacement of the oil seal or
gear shaft
Nature of
Trouble
Probable Cause Countermeasure on
Governor/Controller
Engine Side Governor/Controller Side
3-8
NZ GOVERNOR
3-8. Criteria on Parts Replacement
NOTES;
Replacement Inteval Part Description No. Q'ty
Every disassembly, 2 to 3
yrs. or every 10.000 hrs.
PACKING, governor mtg.
PACKING, governor mtg.
PACKING, press. regulating valve plug
PACKING, base incorporating bolt
PACKING, stopper bolt
PACKING, drain plug
PACKING, pressure regulating valve
WIRE, floating lever
SPRING PIN, fork
COTTER PIN
OIL SEAL, base
O-RING, compensator bush
O-RING, base
O-RING, needle valve
5
6
42-6
51
52
53
55
22
49
50
3
34
35
36
1
1
1
3
1
2
1
2
1
4
1
2
1
1
Every 5 yrs. or 20,000 hrs. GEAR SHAFT
NEEDLE BEARlNG
THRUST WASHER
GUIDE LEVER PIN
OIL SEAL, terminal shaft/speed control shaft
FLOATlNG LEVER
OIL GAUGE
GOVERNOR WEIGHT ASSY.
PRESSURE REGULATTING VALVE ASSY.
4
7
8
12
16
21
26
43
42
1
1
1
2
4
1
1
1
1
Observe the following criteria for replacement of governor parts:
Numbers listed below refer to the corresponding numbers given in the Development, Fig. 5-1.
(1) Replace also parts other than the aforementioned with the new ones if the wear, flaw, rust, etc. are
found as a result of overhaul inspection.
(2) As a general rule, replace those parts used more than 8 years or 40,000 hours by the governor assem-
bly.
CHAPTER 4. REMOTE CONTROLLER
4-1
NZ GOVERNOR
MOTOR CONTROLLER PNEUMATIC CONTROLLER WIRE CONTROLLER
A lever is fitted to the speed control
shaft, and remote control is
done cable
024671-00E
One of three types of remote controllers available for remote control of the governor is equipped to a NZ
Series Governor according to the specified specification.
(Fig. 4-1 shows the appearances of governors equipped with the respective remote controllers.)
This Chapter describes the operation and maintenance of the respective remote controllers.
Fig. 4-1
(Volume:8pages)
4-2
NZ GOVERNOR
4-1. Motor Controller
Changing the compression of the governor spring
by rotation of a motor, the motor controller sets
the governor in any engine speed. A motor
equipped is a reversible, single-phase motor.
In the case of regulating the speed manually, reg-
ulate it by means of the control knob.
Besides, the motor controller of such a specifica-
tion equipping a limit switch to set the upper and
lower limits of the engine speed electrically is also
available.
1) Regulation of the speed
The motor turns while the speed setting switch
is being pushed on the remote control side.
This rotation is decelerated by the gear head,
transmitted to the fork of the governor through
the friction coupling, motor gear, bevel gear,
and spindle screw and changes the compres-
sion of the governor spring to regulate the
engine speed.
In the case of manual regulation, turning the
control knob intermeshes the manual shaft gear
with the motor gear so that the rotation is trans-
mitted to the governor in the same route as in
the case of motor tuning (remote control).
Besides, as the control knob is turned during
remote control (motor turning), the friction
clutch of the friction coupling slips, imparting no
adverse effects on the gear head and motor.
MOTOR CONTROL KNOB
GEAR HEAD
FRICTION
COUPLING
(FRICTION
CLUTCH)
MOTOR GEAR
BEVEL GEAR
SPINDLE SCREW
GOVERNOR
LIMIT SWITCH
MANUAL SHAFT
LIMITER
MANUAL SHAFT
GEAR
WITHOUT LIMITER
Spindle Screw
Bevel Gear Motor Gear Friction Coupling
Gear Belt Filler Plug
Fork
Motor
Motor Gear
Manual Shaft Gear Manual shaft Control Knob
024672-00E
Fig. 4-2
4-3
NZ GOVERNOR
2) Adjustment of the limit switch
The limit switch actuates through a shift based on
the screw action of a limiter incorporated to the
manual shaft. Adjusting the position of the limit
switch through a shift of the limiter by turning the
control knob sets the upper and lower limits of the
engine speed.
When working on this adjustment, either cut
off the power or cover the capacitor with
insulator.
If you happen to touch it, there is a possibil-
ity of an electric shock or a fire caused by a
short
Loosen the limit switch adjusting bolts, and shift
the limit switch in the direction of an elongate
hole of the limit switch guide to adjust the switch
position.
3) Electrical connection of the motor controller
Connect the motor controller as shown in Fig. 4-4
as the motor is a single-phase motor available in
two types of voltage, 110 V and 220 V.
As viewed from the gear head side, the sense of
rotation of the motor is as follows with respect to
the rotation of the engine:
In acceleration: Clockwise
In deceleration: Counterclockwise
Lower Limite Switch
Limiter
Upper Limite Switch
Control
Knob
Screw
Limit Switch Adjusting Bolt
Limit Switch Guide
Capacitor
024673-00E
Fig. 4-3
Fig. 4-4
M
024674-00E
Speed Set
Switch
Acc.
Dec.
Limit Switch Capacitor
Red: AC 200~220 V 0.5 F
Black: AC 100~115 V 2.5 F
RATED POWER APPLICABLE CAPACITOR
Yellow
Blue
4-4
NZ GOVERNOR
4-2. Pneumatic Controller
The compressed air having the specified pressure
is sent into the controller by remote control.
The pressure of the air acted on the diaphragm is
transmitted to the governor spring through the
piston and spindle to change the engine RPM.
The engine RPM can be changed in the same
way as by the compressed air, by turning the con-
trol knob.
1) Maintenance of the controller
Replace the O-ring 22 and diaphragm 7 of the
controller cap 6 with the new ones biennially
or every 10,000 hours even if not damaged.
When disassembling the pneumatic controller,
refer to the Development in Fig. 4-10 and the fol-
lowing procedures:
An encircled numeral appended to a part descrip-
tion appearing in the following text refers to the
corresponding numeral given in Fig. 4-10, Devel-
opment.
(1) Detach the compressed air inlet pipe, loosen
the lock handle 15 of the controller, and
loosen also the control knob 3 until it turns
lightly.
(2) Loosen the clamping bolts 24 and setscrews
26 of the cap 6 with use of a wrench and a
Phillips screwdriver, and remove the cap.
Fig. 4-5
Fig. 4-6
024675-00E
Control Knob
Adjust Screw
Cap
Piston
COMPRESSED
AIR
Diaphragm
Diaphragm Sparing
Push Rod
Max. Speed
Limiting Bolt
O-ring
Filler Plug
3
15
6
26
24
024676-00X
4-5
NZ GOVERNOR
(3) Take out the diaphragm assembly, and re-
move the spring seat 13 and springs 11 & 12.
(4) Lightly insert the width across flats of the tip of
the push rod 8 in a vice stand, loosen the nut
27, and then take out the upper plate 18, dia-
phragm 7 and piston 17.
Disassembly of major parts of the pneumatic
controller is ended with the aforementioned.
Disassemble other parts when and if needed.
2) Reassemble the pneumatic controller in the
reverse sequence of the aforementioned
disassembling procedures.
In this Sub-section, cautions to be taken in reas-
sembling are set forth.
(1) Incorporate the pertinent parts (parts having
asterisked reference numbers in Fig. 4-10)
upon coating the following spots with molyb-
denum disulfide:
Outer periphery of the adjust screw 14,
Both faces of the spring seat 13 and
(10 mm) shaft part of the push rod 8.
(2) Pay your attention to the following points when
incorporating the diaphragm:
Coat the base fabric side of the diaphragm
with molybdenum disulfide.
Parallel the width across flats of the tip of the
push rod with the floating lever of the gover-
nor, and then mount the diaphragm on the
cylinder 5.
Set the protrusion on the outer periphery of
the diaphragm in the groove of the cylinder
5.
Making sure there is no twist nor wrinkle to
the diaphragm, tighten the cap 6.
Don't tighten the nut 27 excessively.
Fig. 4-7
Fig. 4-8
Fig. 4-9
024677-00E
13
12
11
Diaphragm Assy.
27
19
18
7
17
8
024678-00X
Parallel this face with
the floating lever
Cont tighten it excessively
Cylinder
Cap
Base Fabric Side
(molybdenum disulfide coated)
024679-00E
4-6
NZ GOVERNOR
25
19
21
16
1
2
12
11
13
9
10
24
26
19
8
7
27
22
19
18
17
6
30
28
29
23
4
5
15
14
3
20
024680-00E
NOTE: Incorporate this part upon coating it with seizure inhibitor (molybdenum disulfide).
Development & Nomenclature of the Pneumatic Controller
Fig. 4-10
No. Part Description Qty No. Part Description Qty
1 BOLT, max. rotation limiting 1 17 PI STON 1
2 NUT, lock 1 18 PLATE upper 1
3 KNOB, control 1 19 WASHER, spring 8
4 COVER 1 20 PIN, spring 1
5 CYLINDER 1 21 GASKET. copper 1
6 CAP 1 22 O-RING 1
7 DIAPHRAGM 1 23 BOLT M620, collar 4
8 ROD, push 1 24 BOLT M695 2
9 ADJUSTER, spring 1 25 SCREW M616 3
10 NUT, lock 1 26 SCREW M625 2
11 SPRlNG, diaphragm (outer) 1 27 NUT M6 1
12 SPRINC, diaphragm (inner) 1 28 JOINT, swivel pipe 1
13 SEAT. spring 2 29 BOLT, pipe joint 1
14 SCRLW, adjust 1 30 GASKET 2
15 HANDLE, lock 1
16 PLVG, filler 1
4-7
NZ GOVERNOR
4-3. Wire Controller
Fig. 4-11
024681-00E
Speed Control Shaft
Control Knob
With a lever attached to the speed control shaft of
the governor, the wire controller regulates the
engine rotation.
Moreover, turning the control knob can also
change the engine speed in the same way as the
control cable.
6
10
7
9
8
11
1
2
12
5
4
3
024682-00X
Development & Nomenclature of the Wire Controller
Fig. 4-12
1 BREEDER ASSY., filler port combined 1 7 SCREW, adjust 1
2 GASKET, rubber 1 8 SCREW, guide 1
3 NUT, lock 1 9 NUT, lock 1
4 BOLT, max. rotation limiting 1 10 PIN, spring 1
5 COVER 1 11 GASKET 1
6 KNOB, control 1 12 BOLT 4
4-8
NZ GOVERNOR
MEMO
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR
5-1
NZ GOVERNOR
5-1. Cautions in Disassembly/Reassembly
(1) Do not disassemble the governor unnecessarily except in the case of a special repair.
(2) In the case of a repair, have the replacement parts ready in advance.
(3) Prior to the disassembly, have the governor performance and its adjusting spots put on recorded.
Comparing the adjusting values before and after the disassembly makes easy to find out the cause of
a trouble.
Speed droop
Droop adjuster set graduation
Adjusting value of needle valve
Terminal shaft pointer graduation
Speed control shaft pointer graduation
Have a linkage to connect the terminal shaft with the fuel injection pump given with the set mark.
(4) When taking out the governor and after it is removed, pay your attention not to impart a shock to the
terminal shaft, speed control shaft, and gear shaft. (Such a shock may cause a bend of the shaft, a
positional deviation of a shaft bush or a damage of internal parts.)
(5) After the governor is removed cover it so that dust and foreign matter will not enter the governor-driv-
ing device.
(6) Before disassembling the governor, clean its exterior to get rid of adhering dust etc.
(7) Keep a disassembling workbench clean, and use clean light oil for cleaning fluid.
(8) The following tools are necessary for disassembly & reassembly of the governor:
Tool Description Applieation Ref. No. in Fig.5-1
Wrench (10 mm width across fiats)
For detaching & attaching the (controller)
cover
Wrench (12 mm width across flats) For detaching & attaching the stopper bolt 25
Wrench (17 mm width across fiats) For detaching & attaching plugs 54, 42-3
Wrench (24 mm width across fiats)
For detaching & attaching the pressure
regulating valve
42
Pliers or pincers For drawing out a cotter pin and wire 50, 22
Screwdriver, Phillips For adjusting the droop adjuster 60
Screwdriver, blade For adjusting the needle valve 41
Hex. wrench key
(5 mm width across flats)
For detaching & attaching the base 57
Hex. wrench key
(3 mm width across fiats)
For detaching & attaching the terminal
arm setscrew
61
Extractor (3.850 mm) For drawing out the fork spring pin 49
(9) Be sure to change cotter pins, spring pins, wire, copper gaskets and other gaskets with the respective
new ones at time of disassembly.
Refer to Chapter 3 for periodically replacing parts.
Chapter 3, Sec. 3-8. Criteria on Parts Replacement
(Volume:18pages)
5-2
NZ GOVERNOR
48
28
27
34
18
19
49
20
24
21
60
45
44
15
14
13
47
61
7
8
43
50
12
11
17
39
6
55
37
26
1
42
46
33
29
31
32
5
4
6
3
2
1
30
54 53 36 41 56
3
5
51
57
2
4
35
23 59 58 38
25
52
16
40-1
40-1
40
22
10
9
024683-00X
5-2. Development of the Governor
Fig. 5-1
5-3
NZ GOVERNOR
Governor Parts List
1 HOUSlNG 1 36 O-RING, needle valve 1
2 BASE 1 37 NAME PLATE 1
3 SEAL. oil 1 38 NAME PLAT& L, side shaft 1
4 SHAFT, gear 1 39 NAME PLAT& R, side shaft 1
5 GASKET, base 1 40 VALVE ASSY., pilot 1
6 GASKET, cover 1 40-1 BUSHING, pilot valve (1)
7 BEARING, thrust 1 40-2 VALVE, pilot (1)
8 WASHER, thrust 1 41 VALVE, needle 1
9 SPRING, governor 1 42 VALVE, pressure regulating 1
10 FORK spring 1 42-1 BODY (1)
11 LEVER, guide 2 42-2 PISTON (1)
12 PIN, guide lever 2 42-3 PLUG (1)
13 ARM, terminal 1 42-4 SPRING (1)
14 SHAFT, terminal/output 2 42-5 PIN (1)
15 ADJUSTER, droop 1 42-6 GASKET (1)
16 SEAL, oil 4 43 WEIGHT ASSY., governor 1
17 BUSH 4 44 WASHER, droop adjuster 1
18 SHAFT, speed control 1 45 WASHER, droop adjuster toothed 1
19 COLLAR 2 46 RING, compensator lower spring snap 1
20 FORK 1 47 PIN, terminal arm taper 2
21 LEVER, floating 1 48 PIN, compensator piston spring 1
22 WIRE 2 49 PIN, fork spring 1
23 POINTER 4 50 PIN, guide lever pin cotter 4
24 SPRING 1 51 GASKET, base incorporating bolt 3
25 STOPPER 1 52 GASKET, stopper bolt 1
26 GAUGE, oil 1 53 GASKET, drain plug 2
27 BUSH, compensator 1 54 PLUG, drain 2
28 PISTON, compensator 1 55 GASKET, pressure regulating valve 1
29 SPRING, compensator lower 1 56 BEARING, needle 1
30 ROD, compensator 1 57 BOLT, base-incorporating hex. socket 3
31 SPRING, compensator upper 1 58 SCREW, pointer 2
32 PISTON, power 1 59 NUT, pointer 2
33 SPACER, compensator lower spring 2 60 SCREW, droop adjuster 1
34 O-RING, compensator bush 2 61 SETSCREW, terminal arm hex. socket 2
35 O-RING, base 1
5-4
NZ GOVERNOR
1) Loosen four cover clamping bolts with use of
a wrench having 10 mm width across flats,
and remove them together with gasket 6.
2) Turn the governor upside down to discharge
the hydraulic oil.
3) Remove a drain plug on the oil gauge side
from the base 2, and insert the base into the
vice stand for fixing.
4) Straighten with pliers one side of two wires 22
that are coupling the floating lever 21.
Replace the wires 22 with the new ones when
reassembling the governor.
5) Holding the spring fork 10, take out the gover-
nor spring 9 together with the pilot valve 40-2.
(1) Keeping the spring fork and governor
spring not removed from the pilot valve,
soak them in clean light oil.
(2) When taking out the pilot valve pay your
attention not to lose the thrust bearing 7
and thrust washer 8 that might fall out
together.
5-3. Disassembly of the Governor
In time of disassembling (or reassembling) the governor, refer to Fig. 5-1, Development of the Governor
and the following procedures:
An encircled numeral given in a figure of this Chapter or that appended to a part description appear-
ing in the following text refers to the corresponding numeral given in Fig. 5-1, Development of the
Governor.
Fig. 5-2
Fig. 5-3
21
22
024684-00X
10
9
40-2
024685-00X
5-5
NZ GOVERNOR
6) Draw out the cotter pins 50 from the guide
lever pins 12 that are coupling the terminal
arm 13 with the power piston 32, and remove
the guide levers 11 and guide lever pins 12.
As two vertically located cotter pins are
drawn out one at a time, the guide levers
and guide lever pins can be removed.
7) Remove the governor from the vice stand,
place the governor upside down, and using a
hexagonal wrench key having 5mm width
across flats, detach the clamping bolts 57
from the base 2.
When placing the governor upside down, pay
your attention not to lose the thrust bearing 7
and thrust washer 8 in case they are still
remaining inside the governor weight assem-
bly.
Fig. 5-10.
8) Tap the side of the base 2 with a plastic ham-
mer (or mallet), and as it is disjoined from the
housing 1, raise the base straight up to
remove it.
After removing the base, detach the needle
valve 41 from the base by using a blade
screwdriver.
Fig. 5-4
13
50
11
12
32
024686-00X
57
2
024687-00X
Fig. 5-5
Fig. 5-6
2
1
41
024688-00X
5-6
NZ GOVERNOR
9) Remove the pilot valve bushing 40-1 and
gear shaft 4 from the housing and base
respectively.
Temporarily reassemble the removed pilot
valve bushing with already removed pilot
valve, and soak them in clean light oil.
10) Push down the power piston below the gov-
ernor upper part, and remove this piston
together with the compensator bush 27.
Do not disassemble the compensator un it
unless the compensator piston 28 operates
un-smoothly.
11) Using an extractor, draw out the spring pin
49 inside the governor, and remove the
speed control shaft 18, collar 19, fork 20 and
spring 24.
Draw out the speed control shaft as the
pointer 23 kept intact on the shaft
When drawing out the spring pin, pay your
attention so that the speed control shaft
would not bend.
Be careful not to flaw the mating surfaces of
the housing and base.
Fig. 5-7
40-1
4
024689-00X
Fig. 5-8
27
28
024690-00X
Fig. 5-9
24
18
23
19
20
49
024691-00X
5-7
NZ GOVERNOR
12) Unscrew the stopper bolt 25, and remove
the governor weight assembly 43.
If the thrust bearing 7 and thrust washer 8
are remaining inside the assembly, remove
them from it.
13) Disassembly of the terminal shaft unit
Do not disassemble the terminal shaft unit
unless the terminal shaft operates un-
smoothly or its parts have to be replaced.
When replacing parts of the terminal shaft unit,
disassemble this unit according to the following
procedures:
(1) Turn the terminal arm 13 half around, and
hammer the minor diameter side of a taper
pin 47 to remove it.
(2) Using a hexagonal wrench key (having 3 mm
width across flats), unscrew the setscrews
61.
(3) Draw out the terminal shafts 14 , and remove
the terminal arm.
When replacing the shafts and arm, be sure
to replace them as a set since they have
been taper bored together.
Fig. 5-10
43
25
7
8
024692-00X
Fig. 5-11
14
47
61
14
13
61
024693-00X
5-8
NZ GOVERNOR
14) Using a wrench (having 24 mm width across
flats), remove the pressure regulating valve
assembly 42 .
Disassembly of major parts of the governor is
ended with the aforementioned. Disassemble
other parts when and if needed.
Fig. 5-12
42
024694-00X
5-9
NZ GOVERNOR
5-4. Checking of Various Parts
(1) Base
Replace those gear shaft and pilot valve
bushing that have scratch or sliding flaw or
hit mark trace at the gear fit part with the new
ones.
(2) Housing
Replace those gear shaft and pilot valve
bushing that have a flaw at the gear slide
part or those power piston and pilot valve
bushing that have a flaw at the fitting hole
with the new ones.
Replace those terminal shafts and speed
control shaft of which bearing bushes 17
turn as fitted loosely or are worn off by the
housing assembly.
Fig. 5-13
Fig. 5-14
024695-00X
024696-00X
1) Clean
Clean (wash) the disassembled parts in clean cleaning fluid (light oil).
During cleaning, pay your attention not to impart hit marks particularly to the pilot valve, pilot valve
bushing, power piston. needle bearing, thrust washer, etc.
Either wipe the cleaned parts with a clean cloth or blow the dry air against them to dry them.
Check if the holes for hydraulic oil passage in the base and housing have been cleaned neatly.
2) Parts check
Check each parts for crack, damage and rust; and if found defective, correct or replace such a part.
Arrows given in the following figures refer to checking points.
5-10
NZ GOVERNOR
(3) Gear shaft and pilot valve bushing
Replace the gear shaft of which oil seal con-
tacting part is worn off as stepped or of
which the spline part is damaged and pilot
valve bushing of which the outer diameter
(18 mm) is flawed with the new one.
Besides, replace also those parts of which
tooth surface is flawed with the new ones.
Check also whether the spline fit hole on the
governor driving device side is abnormally
worn off or not
(4) Governor weight assembly
Check if the governor weight moves
smoothly.
Check the face sliding with thrust washer at
the weight tip part. If the bearing width is
found to be greater than I mm, replace it by
the weight assembly.
Check that the fitting with the pilot valve
bushing is smooth.
If there is a hit mark, burr, etc., correct such
a part.
(5) Power piston and compensator piston
Incorporate the power piston (in the state of
incorporating the compensator piston 28 and
compensator bushing 27) in the housing, and
check if the power piston operates vertically
under its own weight. Moreover, incorporate
the upper spring 31 and guide lever pins 12
in the power piston; and check that the com-
pensator piston moves smoothly. If opera-
tions of the power piston and compensator
piston are un-smooth and do not improve
even after they are cleaned, replace the
power piston and compensator rod 30.
If operations of the power piston and com-
pensator piston are found bad, this causes a
hunting, excessive s peed droop or bad con-
dition in the engine run.
Fig. 5-15
Fig. 5-16
Fig. 5-17
Spline Part
Gear Shaft
Pilot Valve Bushing
024697-00E
Pilot Valve Bushing
Governor Weight
024698-00E
27
28
024699-00X
5-11
NZ GOVERNOR
(6) Guide levers and speed control shaft
Replace the guide levers 11 and terminal
arm 13 of which 8 mm hole or the guide
lever pins 12 is or are worn off with the new
ones.
Besides, replace the speed control shaft 18,
which is found bent, or the shaft supporting
parts or bushes 17 are found worn off with
the new ones.
(7) Pressure regulating valve
Detach the plug 42-3, take out the spring
42-4 , and check if the piston 42-2 operates
smoothly. If its operation is found catchy or it
is worm off excessively, correct or replace it.
Incorporate the piston with a hole on its end
set at the back.
Fig. 5-18
Fig. 5-19
13
18
11
12
024700-00X
42-2
42-4
42-3
024701-00X
5-12
NZ GOVERNOR
5-5. Reassembly of the Governor
Reassemble the governor in the reverse
sequence of the aforementioned disassembling
procedures.
In this Sub-section, cautions to be taken in reas-
sembly of the governor are set forth.
Replace the O-rings, cotter pins, spring pins,
and gaskets with the respectively new ones, not
use them again.
1) Oil seal and needle bearing
(1) When press fitting the oil seal 3, be careful of
its fitting orientation (in which do not make a
mistake).
(2) When press fitting the needle bearing 56,
position it on the end of the oil seal fitting hole.
If the needle bearing is press fitted exces-
sively, this will block up the hydraulic oil pas-
sage.
2) Incorporation of the terminal shafts
In the case where the terminal shafts are disas-
sembled or replaced with the new ones, incorpo-
rate them according to the following procedures:
(1) When driving in the taper pins 47, hold the ter-
minal arm 13 by hand, and be careful not to
impart a shock to a bush press fitted to the
housing.
(2) After driving in the taper pins, caulk four points
around taper pin holes.
If taper pin driving in and caulking are done
with a strong force, the terminal shafts 14
may bend and cause them to malfunction so
pay your attention to this regard.
13
47
024703-00X
Fig. 5-20
Fig. 5-21
Fig. 5-22
3
56
Hi-pressure
Hydraulic
Oil Passage
Needle Bearing
End
024702-00E
024704-00X
5-13
NZ GOVERNOR
3) Incorporation of the fork
When incorporating the fork 20 to the speed con-
trol shaft 18, insert the spring pin 49 with the
stepped pan of the fork faced up.
4) Stopping of wires from slipping out
After incorporating two wires to couple the fork 20
with the floating lever 21 as wel1 as the spring
fork 10, bend the ends of these wires for stopping
them from slipping out of place.
Bend about 10 mm of the straight part of
wires in 20 to 30 degrees. Round the bend to
the smallest possible radius.
If the bending angle or rounding is large, this
may cause a malfunction of the floating lever.
5) Incorporation of the base
When incorporating the base 2, tighten bolts 57
uniform]y only after checking that the gear shaft 4
can be lightly turned by hand.
If the gear shaft could not be turned lightly by
hand, note that this might damage the
hydraulic oil pump gear, base, etc.
Fig. 5-23
Fig. 5-24
Fig. 5-25
18 49 20
024705-00X
20
10mm
R
30
21
10
024706-00X
4
57
024707-00X
5-14
NZ GOVERNOR
5-6. Service Data in Servicing
No. Item The Point/Procedures Remarks
1 Hydraulic oil SAE#30
Oil volume: Abt. 1.3 ltr.
Oil temperature: 55 to 65C
2 Mounting of the governor Paying your attention so that the center of the gear shaft
does not deviate from the center of the driving stand,
tighten tightening nuts uniformly.
Attach the (controller) cover, and have the control knob
loosened fully.
3 Air bleeding from the
hydraulic oil line
Governor speed: 1.000 10 min
-1
(rpm)
Operate the speed control shaft to actuate the power pis-
ton in full stroke more than ten times
4 Running-in Drive the governor under the No. 3 state for 20 minutes,
and check that no hydraulic oil is
leaking to the exterior.
(Check that there is no change in oil level of the oil
gauge.)
5 Setting of the terminal shaft
pointer in the
"0" position
-1
(rpm)
Turn the speed control shaft in the direction of decelera-
tion (in the SPEED 0 direction)
Set the terminal shaft pointer to the FUEL
0 position, and tighten the pointer screw
6 Checking of the rotation
range of the terminal shafts
Governor speed: 600 10 min
-1
(rpm)
When the speed control shaft in the + and direction,
the terminal shaft should turn promptly and operate over
the full range of the FUEL graduations.
NZ61: FUEL graduations 0 to 7 (0 to 35 deg.)
[Engen Model]
[6N160,6N165]
[6N18,6N21]
This Section sets forth the adjusting (confirming) items at the test stand in time of servicing the governor
as follows:
Set the following items with the droop adjuster set to graduation 5.
(Pay your attention so that the droop adjuster does not contact with the side of the floating lever.)
Make the following adjustments (excluding No. 10 & No. 11) with the needle valve fully opened (set to
open at a position 3 turns back from the completely closed position).
5-15
NZ GOVERNOR
7 Measurement of the operat-
ing torque of the terminal
shafts
-1
(rpm)
Lever length: 200mm
Measure with a spring balancer the reaction force of the
lever when the terminal shafts turn by one graduation in
the FUEL + and directions.
Pressure regulating valve stuck.
The clearance of the power piston and housing
too large.
The clearance of the power piston and( 5 mm)
compensator rod too large.
Side clearance of the hydraulic oil pump gear too
large.
Foreign matter bit in the check valve.
The clearance of the (18 mm) pilot valve bushing
and housing too large.
Fig. 5-26
Operating
torque =
reaction force
N(kgf)0.2 (m)
[Engen Model]
[6N160,6N165]
[6N18,6N21]
8 Positional setting of the
speed control shaft pointer
-1
(rpm)
Turn the control knob, and set the terminal shaft pointer
to the following FUEL graduation:
NZ61: FUEL "6"
NZ61: FUEL "7"
NZ115: FUEL "9"
Set the speed control shaft pointer to the following
SPEED graduation, and tighten the pointer screw:
NZ61: SPEED "8"
NZ61: SPEED "10
NZ115: SPEED "10"
[Engen Model]
[6N160,6N165]
[6N18,6N21]
[Engen Model]
[6N160,6N165]
[6N18,6N21]
9 Checking of the "O" position
of the speed control shaft
pointer
Lower the governor speed from the No. 8 state so that
the terminal shaft pointer assumes the following FUEL
graduation:
NZ61: FUEL "6"
NZ61: FUEL 7
NZ115: FUEL "9
Check the speed when the speed control shaft pointer
indicates the SPEED "0"
NZ61: 500 to 700 min
-1
(rpm)
NZ115: 400 to 600 min
-1
(rpm)
Checking of the droop adjuster graduation.
Positional setting of the speed control shaft pointer.
Incorporation of the governor spring.
Governor weight assembly.
[Engen Model]
[6N160,6N165]
[6N18,6N21]
Governor
Model
Specified pressure
MPa (kgf./cm
2
)
Operating torque
Nm (kgfm)
NZ61 1.18(12)
Greater than
9.8 (1.0)
NZ61 1.47(15)
Greater than
11.8 (1.2)
NZ115 1.47(15)
Greater than 14.7
1.5
Should the operating torque not satisfy value, check
the following parts, and correct or replace them.
Should the governor speed run out of the aforementioned
range, check the following parts.
5-16
NZ GOVERNOR

10 Checking of presence or
absence of a high-pressure
hydraulic oil inflow into the
compensator case
-1
(rpm)
Set the terminal shaft pointer to the FUEL "4.
(Adjust this setting by turning the control knob.)
When the needle valve is changed to the completely
closed state from the fully opened state the terminal
shafts should not turn to the FUEL "0" side by no more
than one degree.
Compensator bush O-rings damaged or dust biting in
of the O-ring grooves, presence or absence or flaw.
The clearance of the(18 mm) pilot valve bushing and
the sliding part of the base too large.
Flaw on the mating surfaces of the base and housing or
biting in of foreign matter.
(0.3 mmand 0.8 mm) escape holes of the needle
valve clogged.
(3 mm) escape hole of the base clogged.
The clearance of the (5 mm) compensator rod and
compensator bush too large.
Fig.5-27
11 Checking of anti-jiggling
performance
Terminal shaft pointer graduation: FUEL 2.
(Adjust this by turning the control knob.)
Needle valve: One turn back from the completely closed
position.
Governor speed: 600. 1,000. 1,500 & 2,000 min
-1
(rpm).
The angle of deflection of the terminal shafts should be
within 0.4
The clearance between the power piston and the hous-
ing too large.
Compensator rod malfunctioned.
Pilot valve control land damaged.
Governor spring incorporated wrongly.
Jiggle of the fork. spring fork and floating lever coupling
part too large.
Side gap of the speed control shaft and terminal shafts
too large.
Fig. 5-28
Should the terminal shafts turn more than 1 degree, check
the following parts. and correct or replace them.
Should the angle of deflection exceed 0.4 degree, check
the following parts, and correct or replace them.
5-17
NZ GOVERNOR
Procedures for Inspecting the Terminal Shaft
Operating Torque
Procedures for Inspecting the Presence or
Absence of High-pressure Hydraulic Oil Inflow
into the Compensator Case
Anti-jiggling Performance Inspecting Procedures
Fig. 5-26
SPEED 0 0
2
2
4
4
6
6
8
8
10
200 mm
FUEL + Dir.
FUEL Dir.
FUEL 1 Graduation
024708-00E
Fig. 5-27
0
0
2
2
4
4
6
6
8
8 10
20 mm
Shift angle: Within 1 Deg.
Control Knob Reading of dial
gauge: Within 0.35 mm
FUEL 4 Graduations 024857-00E
Fig. 5-28
0
0
2
2
4
4
6
6
8
8 10
20 mm
Deflection angle: Within 0.4 deg.
Reading of dial
gauge: Within 0.14 mm
FUEL 2 Graduations 024858-00E
5-18
NZ GOVERNOR
MEMO
Issued by : Precision Equipment Division
Power system Operations Division
and
Quality Assurance Dept.,
Large Power Products Operations Division
Yanmar Co.,Ltd.
Edited by : Yanmar Technical Service Co.,Ltd.
NZ Series Hydraulic Governor
1st Edition : June, 1997
2nd Edition : July, 2002
3rd Edition : July, 2005
4th Edition : July, 2008
Model
NZ61/NZ115
SERVICE MANUAL
I.B.C.No. 0BNZ6-G00100
2008.7.4R

546 E-1

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What is the purpose of this manual?

What is the purpose of this manual?

What are the main sections/chapters covered in this manual?

What are the main sections/chapters covered in this manual?

Even after reading it, carefully keep it, making clear

to all personnel concerned where its kept so that

Priming lever 146673-92920

Lever support 146673-92930

Check of cyl. head bolt tightening force

Disassembly, inspection, cleaning and

Disassembly, inspection, cleaning and

Check of cyl. head bolt tightening force

Disassembly, inspection, cleaning and

Pressure indicator 137600 - 93751

Priming lever 146673 - 92920

Lever support 146673 - 92930

Body of fuel injection valve drawing-out tool 146673 - 92340

Drawing-out bolt 146673 - 92330

Nut 26732 - 160002

Battery fluid When handling the battery fluid, wear rubber

Rubber hose, 3 m long 1

Rubber hose, 1 m long 4

Coupler, internal threaded 4

Lifting tool body 146673 - 92310

Cap nut 146673 - 92320

Eye nut 26620 - 160002

Bolt 26116 - 160452

Drawing-out bolt 146673 - 92330

Nut 26732 - 160002

Rotator retainer 141616 - 92330

Handle support 146673 - 92360

Handle 139653 - 92340

Bolt 146673 - 92350

Nut 26706 - 120002

Nozzle sleeve disassembling tool 146673 - 92250

Drawing-out plate, protection ring 146673 - 92060

Liner drawing-out upper implement 146673 - 92010

Spacer 139653 - 92040

Liner drawing-out upper

Liner drawing-out lower

Lock nut 26772-240002

Drawing-out bolt 26206-121554

Circular nut 146673-92110

Upper metal detaching/

Upper metal inserting

Notch (pawl) Notch (pawl)

Solution inject Port

Width of pump gear

Outer dia. of pump gear

Width of pump gear

Inner dia. of oil shield

Though this Parts List has been edited to

Example of item & indication necessary at the

Fig 11 CAMSHAFT & LUB. OIL PUMP DRIVING

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